1.6L petrol engines
Removing
1. Remove the ground wire from the battery.
2. Drain the coolant from the cooling system.
3. Remove a gear belt and a back casing of a gear belt.
4. Unscrew the three mounting bolts and remove the water pump. Remove the O-ring from the water pump.
Installation
1. Check that the mating surfaces of the water pump and cylinder block are clean and dry. Apply a thin coat of sealant to the mating surface of the cylinder block.
2. Fit a new O-ring to the water pump and install the pump to the cylinder block. On SOCH engines, check that the lugs on the pump and cylinder block are aligned. On DOCH engines, align the edge of the pump protrusion with the mark on the cylinder block (arrow).
3. Establish bolts of fastening of the water pump and tighten them the demanded moment.
4. Install the rear toothed belt guard and toothed belt.
5. Pour coolant into the cooling system.
6. Connect the battery.
Doch 1.8 and 2.0 L petrol engines
Removing
1. Remove the ground wire from the battery.
2. Drain the coolant from the cooling system.
3. Remove the toothed belt and tensioner.
4. Unscrew the three mounting bolts and remove the pump. Remove the o-ring from the pump.
Installation
1. Check that the mating surfaces of the pump and cylinder block are clean and dry and apply a light coat of silicone-based lubricant to the mating surface of the cylinder block.
2. Fit a new O-ring to the pump and install the pump to the cylinder block. Check that the lugs on the pump and cylinder block are aligned.
3. Install the pump mounting bolts and tighten them to the required torque.
4. Install the rear toothed belt guard and toothed belt.
5. Connect the battery.
6. Pour coolant into the cooling system.
Diesel engine 1.7L
Removing
1. Remove the ground wire from the battery.
2. Drain the coolant from the cooling system.
3. Remove the auxiliary drive belt.
4. Fix the water pump pulley from turning, unscrew the fastening nuts and remove the pulley from the pump flange.
5. Unscrew the pump mounting bolts and remove the pump from the cylinder block. Remove the gasket.
Installation
1. Check that the mating surfaces of the pump and cylinder block are clean and dry.
2. Install the pump to the cylinder block with a new gasket and secure with bolts.
3. Install the water pump pulley.
4. Install and adjust the tension of the auxiliary drive belt.
5. Connect the battery.
6. Pour coolant into the cooling system.
Diesel engine 2.0L
Removing
1. Remove the ground wire from the battery.
2. Drain the coolant from the cooling system.
3. Remove the auxiliary drive belt.
4. Remove the air filter cover.
5. Raise the front of the car and secure it on stands.
6. Remove the lower engine mudguard.
7. Remove the nut from the top of the right powertrain mount.
8. Using a jack, raise the engine to make room for the water pump to be removed.
9. Secure the water pump pulley against turning and unscrew the pulley mounting bolts. Remove the pulley from the pump.
10. Remove the three water pump mounting bolts.
11. Remove the water pump from the engine block.
12. Remove the o-ring from the pump.
Installation
1. Check that the mating surfaces of the pump and cylinder block are clean and dry, and apply a thin layer of silicone-based lubricant to the mating surface of the cylinder block.
2. Install a new O-ring to the water pump.
3. Install the pump in the cylinder block and secure with bolts.
4. Install the water pump pulley.
5. Lower the engine and tighten the right suspension nut of the power unit.
6. Install the mudguard and lower the car.
7. Install the air filter cover.
8. Install and adjust the tension of the auxiliary drive belt.
9. Connect the battery.
10. Pour coolant into the cooling system.
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