Removal for engines E1, E3, E5
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Remove lower engine cover -1-.
3. Drain and collect coolant.
4. Loosen the water pump pulley bolts.
5. Remove V-belt -2-, see Chapter Gasoline engines, Chapter Removing and installing/tensioning the V-belt.
6. Unscrew the water pump pulley -5-.
7. Disconnect the coolant hose -3- after loosening the clamp.
8. Unscrew the water pump mounting bolts -5- and remove the water pump from the bypass system pipe -4-.
Installation
1. Put on the bypass pipe new gasket.
2. Insert the water pump so that the overflow pipe is completely seated in the pump. Tighten the fastening bolts 30 Nm.
3. Check that the water pump rotates freely and does not catch anywhere.
4. To put on a hose of a cooling liquid and to fix a collar.
5. Install the belt pulley and tighten by hand.
6. Install the V-belt, see Chapter Gasoline engines, Chapter Removing and installing/tensioning the V-belt.
7. Tighten the belt pulley bolts.
8. Fill in coolant.
9. Connect the mass cable to the battery.
10. If available, set the clock and set the radio security code.
11. After a test drive, check the tightness of the cooling system.
Removal for engines B3, B5, B6, BP
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Drain and collect coolant.
3. Remove the belt cover and the toothed belt itself, see Chapter Gasoline engines, Chapter Removal and installation of a gear belt of engines B3, B5, B6 (SOHC), VR (SOHC).
4. VR engine (DOHC): Remove the oil dipstick and unscrew the dipstick guide tube.
5. Unscrew water fitting -1- and remove from overflow pipe -3-.
6. VR engine (DOHC): Unscrew guide and tension rollers with spring.
7. To unscrew bolts of fastening of the water pump -5- and to remove the pump.
Installation
1. Clean the sealing surfaces on the cylinder block, water pump and water fittings first with a scraper, then wipe with a rag to remove seal residue.
2. Carefully insert new pump -5- with new gasket -6-. Tighten the bolts 25 Nm.
3. VR engine (DOHC): Install the guide and tension rollers with a spring and tighten with force 45Nm.
4. Fit a new gasket -4- onto the overflow line -3-.
5. Install water pipe -1- with new gasket -4- and tighten firmly 25 Nm.
6. Install and tighten the toothed belt, see Chapter Gasoline engines, Chapter Removal and installation of a gear belt of engines B3, B5, B6 (SOHC), VR (SOHC).
7. Fill in coolant.
8. Connect the mass cable to the battery.
9. If available, set the clock and set the radio's security code.
10. Warm up the engine. Then park the vehicle on a dry surface and check the cooling system for leaks.
Removal for diesel engine
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Drain and collect coolant.
3. Remove the belt cover and the toothed belt itself, see Chapter Gasoline engines, Chapter Removal and installation of a gear belt of engines B3, B5, B6 (SOHC), VR (SOHC).
4. Pull out the oil dipstick and unscrew the guide tube -2- of the dipstick.
5. To unscrew bolts of fastening of the water pump -3- and to remove the pump.
Installation
1. Clean the sealing surfaces on the cylinder block, water pump and water fittings first with a scraper, then wipe with a rag to remove seal residue.
2. Carefully insert new pump -3- with new gasket -4-. Tighten the bolts 25 Nm.
3. Screw the guide tube -2- oil dipstick firmly 25 Nm and insert the dipstick.
4. Insert new gaskets -1-.
5. Install and tighten the toothed belt, see Chapter Gasoline engines, Chapter Removal and installation of a gear belt of engines B3, B5, B6 (SOHC), VR (SOHC).
6. Fill in coolant.
7. Connect the mass cable to the battery.
8. If available, set the clock and set the radio security code.
9. Warm up the engine. Then install the car in a dry place and check the tightness of the cooling system.