- Drain the coolant from the cooling system (section 4.1) or disconnect the lower water hose and drain the coolant. Pour the liquid that looks good into an appropriate container.
- Unscrew the timing belt protective covers from the front of the engine. The two bolts located above the crankshaft belt pulley do not need to be unscrewed.
- Remove the timing belt following the instructions for the appropriate engine and support the right side of the engine with a jack (place a wooden block between the jack and the engine). Slowly raise the engine until the suspension is relieved. Remove the suspension from this side.
- Disconnect the water hoses from the water pump and remove the pump mounting bolts. Remove the water pump from the cylinder block. There is a circular sealing ring under the pump (tU type engines) or gasket (xU type engines). They must be replaced.
On a TU type engine, the water pump can be partially disassembled to replace both internally located O-rings, the impeller assembly, or the pump cover. The disassembled pump is shown in Figure 160. Insert new O-rings into the grooves and reassemble the pump. Tighten the upper bolts to 16 Nm and the lower bolts to 7 Nm.
The water pump on XU type engines is replaced as a single unit.
Installation of the assembled water pump is carried out in reverse order. Before installation, check that both pump centering pins are in the cylinder block (CU). Insert a new O-ring into the cylinder block and install the housing. Insert the bolts and tighten them to the specified tightening torque for TU type engines. Tighten bolts (2) in Figure 161 to 30 Nm and bolts (3) to 65 Nm. Connect the water hoses. Install the timing belt following the instructions section 2.3 for engine assembly. After this, tighten the engine mount to a torque of 45 Nm, add coolant to the cooling system and, after running the engine for some time, check for leaks.
On a Type XII engine, the 5 bolts shown in Figure 162 are tightened to a torque of 15 Nm. The pump gasket must be replaced.
The water pump of the TU engine can also be partially removed, i.e. the impeller unit or cover can be removed separately when, for example, only the O-ring needs to be replaced. In this case, the coolant is drained and the toothed belt is removed, as when completely removing the water pump.
- To remove the impeller assembly, unscrew the two bolts (1) and (2) (Figure 163). Remove the impeller assembly (3). Insert a new O-ring into the groove and reinstall the impeller assembly.
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Figure 160. Parts of the water pump of the TU type engine. 1. Impeller assembly; 2. Housing cover; 3. Water pump housing
Figure 161. Installing a water pump on a TU type engine. 1. Water hose nipple; 2. Bolt, 30 Nm; 3. Bolt, 65 Nm; 4. Water hose
Figure 162. The arrows indicate the water pump mounting bolts on the XU type engine.
Figure 163. Removing the impeller assembly (see text).
Tighten bolt (1) to a torque of 16 Nm and bolt (2) to a torque of 7 Nm. Install the timing belt following the engine assembly instructions.
- To replace the housing cover (2) in Figure 160, the toothed belt does not need to be removed. However, the coolant must be drained. Remove the cover and pull the O-ring out of the groove. Place a new O-ring into the groove and reinstall the cover onto the water pump housing. The bolts are tightened to a torque of 7 Nm.