WATER PUMP - R + R

Operation 1088C10 · WATER PUMP AND THERMOSTAT

1.9 JTS, 2.2 JTS

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4410D16 BRACKET (ONE) RETAINING CHASSIS TO BODY - R R

(right side).

1. Undo the coolant drain plug in the water pump and drain the coolant.

Collect the coolant in a suitable container.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

2. Loosen the collar and disconnect the upper coolant input sleeve to the radiator, thermostat side.

3. Loosen the bands and disconnect the coolant delivery and return pipes to the climate control system heater, thermostat side.

4. Undo the engine coolant temperature sensor and remove it.

The engine coolant temperature sensor is removed to gain access to one of the thermostat fixing bolts.

5. Undo the bolts (5a) and remove the thermostat (5b) complete with water pump rigid fluid inlet pipe (5c) and O-rings (5d).

1. Loosen the nut fixing the electric wiring mounting bracket.

2. Undo the bolts (2a) and remove the water pump cover (2b), complete with seal.

1. Undo the bolts (1a) and remove the water pump service cover (1b) from the timing chain cover.

2. Remove the gasket.

1. Fit the tool (1a) for securing the water pump drive pulley and fasten with two bolts (1b) to the timing chain cover and with three bolts (1c) to the water pump drive pulley.

2. Undo the three bolts fixing the drive pulley to the water pump.

3. Undo the two bolts fixing the water pump to the engine block.

The lower bolt should not be extracted on account of its length.

1. Undo the remaining bolt (1a) and remove the water pump (1b) complete with O-ring.

Refitting

-Clean the surfaces of the water pump.

- Place the water pump, complete with new O-ring in its housing and secure it tightening the bolts to the recommended torque.

- Tighten the bolts fixing the drive pulley to the water pump to the recommended torque.

- Remove the tool used for securing the water pump drive pulley.

1. Place the water pump cover (1a), complete with a new seal, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

Spread the sealing ring with silicone grease (white).

Pay attention to the centering bushes.

2. Tighten the nut fixing the electric wiring mounting bracket.

1. Tighten the coolant drain plug to the water pump to the recommended torque.

Apply sealant to the plug before fitting it.

1. Place the water pump service cover (1a), complete with a new gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

1. Place the thermostat (1a) complete with water pump rigid coolant inlet pipe (1b) and new O-rings (1c) back in its housing and secure it tightening the bolts (1d) to the recommended torque.

Apply (white) silicon grease to the O-rings.

2. Place the engine coolant temperature sensor in its housing and tighten it to the recommended torque.

3. Connect the coolant delivery and return pipes to the climate control system heater, thermostat side, and tighten the band.

4. Connect the upper coolant input sleeve to the radiator, thermostat side, and tighten the band.

5. Connect the electrical connection to the engine coolant temperature sensor.

Op. 4410D16 BRACKET (ONE) RETAINING CHASSIS TO BODY - R R

(right side).

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

- Connect the negative battery terminal.

Op. 0010T20 ENGINE COOLANT - CHANGE

- Remove the vehicle from the lift.

2.4 JTD 20V

- On this car, it is not possible to remove/refit the water pump on the car.

To perform this operation, remove/refit the power unit

Op. 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

and then work at the bench, customising the engine service procedures for this operation.

3.2 JTS

Removing

- Position the vehicle on a lift.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 1088C22 WATER PUMP PULLEY - R.R.

1. Undo the bolts fixing the water pump to the timing drive chain cover.

- Remove the gasket.

Refitting

- Refit the water pump, complete with new gasket, in its housing and secure it using the bolts.

Op. 1088C22 WATER PUMP PULLEY - R.R.

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

- Remove the vehicle from the lift.