Pump mounting bolts
Removal
1. Disconnect the ground wire from the battery and drain the fluid from the cooling system.
2. Remove the radiator and fan.
3. Disconnect the flexible hose leading to the heater from the coolant pump.
4. Remove the timing belt cover.
5. Remove the flexible coolant hose between the coolant pump and the radiator.
6. Unscrew the 3 coolant pump mounting bolts and remove the pump completely.
Repair
1. Remove the pump drive pulley using a press.
2. Remove the pump shaft assembly with seal, precision bearing and rotor from the pump housing.
3. Remove the seal from the pump shaft and remove the precision bearing from the pump body.
4. Using a ring and a shank of the appropriate diameter and length, move the pump pulley hub on the pump shaft so that the end of the shaft protrudes 1.5 mm above the outer surface of the hub.
5. Install the new seal onto the pump shaft and into the recess in the housing.
6. Install the rotor on the pump shaft so that the gap between its blades and the pump body is 0.8 mm.
Installation
1. Clean the mating surfaces of the pump housing and engine cylinder block.
2. Install the pump together with a new gasket on the cylinder block.
3. Install the timing belt cover.
4. Connect the flexible hoses to the coolant pump, connecting the pump to the radiator and heater.
5. Install the radiator and fan.
6. Adjust the tension of the V-belt (1 – tensioner bolt, A – belt deflection (A = 10 mm)).
7. Fill the cooling system, connect the battery and check the tightness and operation of the cooling system. If necessary, top up the coolant level.
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