Petrol engines 1.2, 1.4 and 1.6 l
1. Disconnect the negative cable from the battery.
2. Drain the coolant into a clean container and immediately put the hose back on and secure it.
3. Remove the toothed belt (see chapter Engines).
4. On engines OHC 1.2 and 1.4 l remove the rear toothed belt cover (see chapter Engines), for which unscrew the mounting bolts and remove the camshaft bed cover, gears of the camshaft and crankshaft, as well as the tension roller from the oil pump housing.
5. Turn out bolts of fastening and remove the water pump (shown engine OHC 1.2 or 1.4 l).
Water pump mounting bolts
6. Clean the mating surfaces of the pump and cylinder block.
7. To prevent corrosion of the water pump, lubricate the surface of the cylinder block mating with it, as well as the sealing ring in the pump housing, with silicone grease, for example, OPEL 19 70 206 (90 167 353).
8. Install water pump with new o-ring (2) in the block of cylinders and tighten bolts of its fastening with force 8 Nm.
On DOHC 1.4 and 1.6 L engines, install the pump so that the mark (2) on the pump matched the mark (1) on the cylinder block
O-ring for water pump
Mounting marks
9. On engines OHC 1.2 and 1.4 l install the rear cover of the toothed belt, tighten the bolts of its fastening with force 12 Nm, and install the crankshaft gear, making sure the TDC marks match (see chapter Engines).
10. On engines OHC 1.2 and 1.4 l Install the toothed belt tensioner. Pay attention to installation position: presser foot (1) the roller strip must fit into the hole (2) oil pump housing The tab should go into the hole all the way to the right. Torque the bolt 20 Nm.Install the camshaft gear (see chapter Engines).
Installing the toothed belt tensioner
12. Put on the toothed belt and tighten it (see chapter Engines).
13. On engines OHC 1.2 and 1.4 l install the camshaft bed cover with a new seal and tighten the mounting bolts with force 8 Nm.
14. Prime the cooling system.
Gasoline engines DOHC 1.0 and 1.2 l
1. Remove the cap of the expansion tank and thereby release the pressure in the cooling system.
2. Drain the coolant.
3. Remove the air filter with the MAF sensor.
4. Give bolts of fastening of a pulley of the water pump.
5. Turn the V-belt tensioner by the center bolt in a clockwise direction to displace the tensioner against the spring force.
Auxiliary drive belt loosening
6. Fix the position of the tensioner.
7. Remove the V-belt from the pulley.
8. Turn out the bottom bolt of fastening of a tensioner and incline it towards the generator.
9. Remove the coolant hoses from the pump.
10. Disconnect the ECT sensor connector (2) and clean the timing case.
Connector (2) ECT sensor and water pump mounting bolts: 1 - short bolts, arrows - long bolts
11. Turn out bolts of fastening and remove the water pump (arrows and 1 in the illustration).
12. Clean the mating surfaces of the pump and timing case.
13. Install a new gasket on the timing case and insert the guide bushings.
Water pump gasket and guide bushings
14. Install the water pump and tighten the bolts of its fastening with force 8 Nm.
Screw the short bolts into the holes (1), and long bolts into the holes marked with arrows (refer to illustration).
15. Tighten the lower V-belt tensioner mounting bolt to 20 Nm.
16. Put on the V-belt and tighten it (see chapter Vehicle settings and routine maintenance).
17. Install the air filter with the MAF sensor.
18. Prime the cooling system.
Diesel engine
1. Disconnect the negative cable from the battery.
2. Drain the coolant into a clean container, then immediately put on the hose and secure it.
3. Remove the air filter and air intake sleeve.
4. Remove the V-belt.
5. Remove the water pump pulley bolts and remove the pulley. When removing the bolts, hold the pulley with an oil filter puller, for example, HAZET 2170.
Bolts of fastening of a pulley of the water pump
6. Raise the engine slightly.
Using a special tool to lift the engine
7. Turn out bolts of fastening of a damping support of the engine to the holder on the block of cylinders.
Bolts of fastening of a damping support of the engine to the holder
8. Carefully lower the engine and remove the V-belt pulley.
9. Turn out bolts of fastening of the water pump and take out it together with a guide from the block of cylinders.
Water pump mounting bolts
10. Clean the mating surfaces of the pump and cylinder block.
11. Insert the coolant channel guide into the cylinder block.
coolant channel guide
12. Install the pump with a new gasket in the cylinder block and tighten the pump mounting bolts with force 20 Nm.
13. Install the pump pulley.
14. Raise the engine.
15. Fasten the engine damping mount to the holder with force 60 Nm.
16. Lower the engine.
17. Tighten the water pump pulley fasteners with force 20 Nm.
18. Install the V-belt and tension it.
19. Install the air filter and air intake sleeve.
20. Prime the cooling system.
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