Water pump — removal and installation (Opel Ascona C)

1. Drain the coolant (see section 3).

2. Loosen the nuts and bolts securing the generator, turn it towards the engine and remove the drive belt.



3. Loosen the mounting bolts and remove the camshaft timing belt. Turn the crankshaft so that the mark on the camshaft sprocket aligns with the mark on its housing (behind the star), and the notch on the rim of the crankshaft pulley aligned with the indicator.

4. Loosen the 3 bolts securing the pump to the cylinder block. The pump shaft is eccentric in relation to its housing, so that by turning the pump housing, the tension can be removed from the camshaft timing belt. Rotate the pump housing inward to relieve tension on the belt and remove the belt from the pump pulley. There are special chamfers on the pump body behind the pulley that allow the body to be turned using a large thin wrench. Alternatively, the pump can be turned from below (from under the car), tapping it with a hammer through a long beard. Check that the position of the crankshaft and camshaft does not change when removing the belt, as this may not only disrupt the valve timing, but also lead to damage to the pistons or valves. Loosen the bolts and remove the rear camshaft belt shield. Remove the pump from the cylinder block (see photos).







5. Although in principle the pump can be disassembled, this requires a press and special tools. Therefore, we recommend simply replacing the faulty pump.

6. Before installing the pump, clean its seat in the cylinder block and install a new sealing ring on the pump body. Apply silicone grease to the ring and the sealing surface of the cylinder block. Install the pump in place and secure it with bolts and washers, tightening them by hand at this stage (see photos). The cutout in the pump flange must be positioned as shown in the photographs as it acts as a stop when you turn the pump housings to tighten the timing belt. Install the rear belt shield in place.







7. Put the toothed belt on the pump pulley and tighten it (see chapter 1). Tighten the 3 bolts securing the pump to the required torque.

8. Replace the belt cover and place the alternator drive belt on the alternator and crankshaft pulleys. Tighten the belt and secure the generator (see section 10).

9. Fill the system with coolant (see section 6). Start the engine, bring it to normal operating temperature and check the pump for leaks.