Removal and installation
Engine 2.0 l OHC until the end of 1996
1. Drain the coolant (section Filling the cooling system coolant Chapters Routine care and maintenance).
2. Remove the timing belt as described in Chapter Engine.
3. Loosen the mounting bolts and remove the coolant pump (1) in the illustration. from the cylinder block. Clean the mating surface immediately.
When installing a pump in a car workshop, a special one is used (silicone) grease. This grease is applied around the circumference of the mating surface of the pump. Install the pump with a new sealing ring onto the cylinder block. Tighten the bolts to a torque of 25 Nm.
4. Install the timing belt and adjust its tension as described for the OHC engine (section Camshaft drive Chapters Engine).
Finally, fill the system with coolant. Start the engine and check the system for leaks.
Engine 2.0 l OHC since 1997
1. Drain the coolant (section Filling the cooling system coolant Chapters Routine care and maintenance).
2. Remove the timing belt as described for the 2.0L OHC engine (section Camshaft drive Chapters Engine).
3. Loosen the mounting bolts and remove the timing belt tension roller.
4. Disconnect the crankshaft position sensor cable from the clamps on the inside of the timing belt cover.
Loosen the bolts and remove the coolant pump (1) from the cylinder block see fig. Clean the mating surface of the cylinder block immediately.
When installing a pump in a car workshop, a special one is used (silicone) grease. This grease is applied around the circumference of the mating surface of the pump.
5. Install the pump with a new sealing ring onto the cylinder block. The protrusion on the pump must fit into the groove (2) on the cylinder block. The mating location is shown in the illustration. Tighten the bolts to a torque of 25 Nm.
Install the timing belt tensioner roller.
Install the belt and adjust its tension as described for the 2.0L engine from 1997 (section Camshaft drive Chapters Engine).
Finally, fill the system with coolant. Start the engine and check the system for leaks.
DOHC Engine
Removal and installation of the coolant pump is performed similarly to the description for the 2.0 l engine from 1997.
The toothed belt is removed, installed and tensioned in the same way as described for the DOHC engine (section Camshaft drive Chapters Engine).
Engine 2.4 l
1. Disconnect the ground cable from the battery.
2. Remove the fan cover and hang it on the impeller.
3. Remove the viscous coupling.
4. If equipped with air conditioning, remove the compressor drive V-belt.
5. Remove the V-belt from the oil pump and generator drive.
6. Remove the crankshaft pulley while holding the shaft from turning (put the gear on).
7. Disconnect the hoses from the coolant pump and thermostat. Please note the location of the individual hoses. Incorrectly connected hoses can cause serious engine damage.
8. Loosen the bolts as shown in the illustration and remove the pump from the timing case cover.
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9. Thoroughly clean the mating surfaces of the pump and cover and install a new gasket. Install the pump in place and tighten the mounting bolts to 120 Nm. Fit and tension the V-belt as described earlier. The same applies to the air conditioning compressor drive belt.
Finally, fill the cooling system with liquid as described in the relevant section and check the system for leaks.
Coolant pump repair
The coolant pump cannot be repaired and must be replaced if damaged. After removal, the pump is checked for leaks (visible by the presence of rust spots) and the hub is rotated to check the bearings.
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