Disassembling the pump is quite a labor-intensive job, so if it malfunctions, we recommend replacing the pump assembly.
You will need: an 8mm socket, a flat-blade screwdriver, and all the tools needed to remove the air conditioning compressor belts (see "Replacing the Air Conditioning Compressor Drive Belt"), auxiliary drives (see "Replacing the accessory drive belt") and the timing drive (see "Replacing the timing belt").
1. Drain the engine cooling system (see "Replacing the coolant").
2. Remove the air conditioning compressor drive belt (see "Replacing the Air Conditioning Compressor Drive Belt").
3. Remove the accessory drive belt (see "Replacing the accessory drive belt").
4. Remove the timing belt (see "Replacing the timing belt").
WARNING: After removing the timing belt, do not rotate the crankshaft or camshafts, as this may damage the valves with the pistons.
NOTE: It is only necessary to remove the timing belt on vehicles produced since April 2005, as these vehicles have a belt tensioner roller mounted on the water pump housing. On vehicles produced before April 2005, the tensioner roller is mounted on the engine block and it is not necessary to remove the belt when replacing the water pump.
Fig. 5.22. Water pump: 1 – timing belt tension roller; 2 – water pump; 3 – bolts for fastening the water pump to the engine cylinder block; 4 – bolt securing the tension roller to the water pump housing
5. Unscrew the six bolts 3 (Fig. 5.22) securing the water pump 2 to the engine cylinder block, use a screwdriver to pry up the water pump housing and remove the pump together with the timing belt tension roller.
NOTE: The timing belt tension roller is secured to the water pump housing with bolt 4.
6. Remove the gasket installed between the water pump housing and the engine cylinder block.
CAUTION: Always replace the water pump housing gasket with a new one whenever it is removed, regardless of its condition.
7. If the new water pump does not have a timing belt tension roller, unscrew bolt 4 securing the roller to the pump body and install the roller on the new pump. Tighten the roller mounting bolt to a torque of 28 N·m.
8. Install the water pump in the reverse order of removal. Tighten the pump mounting bolts evenly in a crisscross pattern to a torque of 10 N·m.
HELPFUL TIP: Apply a thin layer of sealant to the water pump housing gasket on both sides.
9. Install the timing belt and adjust its tension (see "Replacing the timing belt").
10. Install the remaining parts in the reverse order of removal.
WARNING: Replace the accessory and air conditioning compressor drive belts with new ones, as they cannot be reused once removed.
11. Fill the coolant and remove air locks from the cooling system (see "Replacing the coolant").