[93 03-07]
 | CAUTION: Coolant system may be HOT and under PRESSURE |
Water Pump Installation:
| STEP 1 | Carefully undo the cap on the expansion tank to release any pressure. |
| STEP 2 | Unplug the oxygen sensors and temperature sensor and carefully lower the cables. |
| STEP 3 | Unplug the mass air flow sensor. |
| STEP 4 | Detach the hose from the mass air flow sensor. |
| STEP 5 | Remove the cover on the air box. |
| STEP 6 | Remove the air filter. |
| STEP 7 | Detach the air inlet hose from the air box. |
| STEP 8 | Remove the air box. Make sure that the AC pressure sensor is not damaged when the air box is removed. |
| STEP 9 | Remove the inlet hose to the turbocharger, cover the turbocharger inlet. |
| STEP 10 | Remove the upper bolt for the water pump in the timing cover and engine block. |
| STEP 11 | Remove the heat shield over the turbocharger. |
| STEP 12 | Remove the upper oxygen sensor. |
| STEP 13 | Remove the nuts for the catalytic converter connection with the turbocharger. |
| STEP 14 | Undo the bolt for the turbocharger oil delivery pipe. |
| STEP 15 | Raise the car slightly. |
| STEP 16 | Remove the front right wheel. |
| STEP 17 | Lift the car a little more. |
| STEP 18 | Remove the front spoiler shield . |
| STEP 19 | Remove the right wing liner. Conv: Remove chassis reinforcement, front sub frame. |
| STEP 20 | Place a container under the car, connect a hose to the radiator and drain the coolant. |
| STEP 21 | Remove the lower bolt for the water pump in the timing cover and engine block. |
| STEP 22 | Place a container under the car and connect a hose to the water pump drain plug. Open the plug to drain the coolant. |
| STEP 23 | Mark the direction of rotation, release the belt tensioner using a ratchet and remove the belt. |
| STEP 24 | Remove the lower turbocharger pressure pipe. |
| STEP 25 | Remove the front pipe. |
| STEP 26 | Remove the heat shield over the steering gear. |
| STEP 27 | Remove the heat shield over the catalytic converter. |
| STEP 28 | Remove the lower oxygen sensor. |
| STEP 29 | Remove the catalytic converter bracket from the engine block. |
| STEP 30 | Remove the catalytic converter. |
| STEP 31 | Remove the turbocharger coolant pipe from the thermostat housing and the turbocharger. |
| STEP 32 | Remove the bolts on the thermostat housing. |
| STEP 33 | Remove the water pump cover from the timing cover. |
| STEP 34 | Hold the water pump using a tool so you can secure the balancer shaft pinion. |
| STEP 35 | Remove the pinion bolts. Use a magnetic socket to remove the bolts from the holder. |
| STEP 36 | Remove the bolts on the back of the water pump. |
| STEP 37 | Move aside the thermostat housing along with the hoses and remove the coolant pump. It is normal for a very small amount of coolant to pass through the coolant pump shaft seal in order to lubricate it. |
| STEP 38 | Remove the water pipe from the thermostat housing. |
Installation Instructions:
| STEP 39 | Clean and fit new O-rings on the coolant pipe, lubricate sparingly with Vaseline, non-acidic. |
| STEP 40 | Clean the connections on the thermostat housing, install a new seal and install the water pipe. |
| STEP 41 | Install the stud to the water pump driver. |
| STEP 42 | install the water pump with a new seal, sparingly lubricated with Vaseline, non-acidic, by guiding in the stud through one of the holes in the balancer shaft sprocket. |
| STEP 43 | Insert the water pump bolts, the two rear bolts and the lower bolt through the timing cover. |
| STEP 45 | Tighten the water pump bolts. Torque the short bolts to 20 Nm (15 ft lbs). Torque the long bolts to 25 Nm (18 ft lbs). |
| STEP 46 | Install the coolant pipe to the pump and fit the thermostat. Torque to 10 Nm (7 ft lbs) |
| STEP 47 | Install the coolant pipe between the turbocharger and the thermostat housing with new seals. Torque to 20 Nm (15 ft lbs). |
| STEP 48 | Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection. |
| STEP 49 | Insert the catalytic converter bracket bolts into the engine block and add new nuts to the studs. |
| STEP 51 | Lubricate the turbocharger studs with screw lubricant. |
| STEP 52 | Install the catalytic converter with new nuts so that it is firmly against the turbocharger. Torque to 10 Nm (7 ft lbs) |
| STEP 53 | Tighten the turbocharger oil delivery pipe using new seals. Grip the pipe so that it does not rotate. Torque to 15 Nm (11 ft lbs) |
| STEP 55 | Tighten the catalytic converter nuts and bolts again to make sure they are tight. Torque bolts to 25 Nm (18.5 ft lbs) |
| STEP 56 | Lubricate the threads sparingly with screw lubricant and fit the lower oxygen sensor. Torque to 40 Nm (30 ft lbs). Make sure that the oxygen sensor cables are not damaged. |
| STEP 57 | Lift up the oxygen sensor cable, make sure the cable is straight and clean. |
| STEP 58 | Install the heat shield onto the catalytic converter. |
| STEP 59 | Install the heat shield over the steering assembly. |
| STEP 60 | Clean the connection on the catalytic converter and the exhaust connection to the front muffler. Install the joint clamp. |
| STEP 61 | Fit the front pipe with a new gasket, new nuts and rubber mounts. Lubricate the studs with screw lubricant. |
| STEP 62 | Move over the exhaust joint clamp so that the pipe ends are in the middle of the clamp. |
| STEP 63 | Tighten the joint clamp at the catalytic converter. Torque to 25 Nm (18.5 ft lbs). |
| STEP 64 | Torque the joint clamp nuts. Torque to 40 Nm (30 ft lbs). |
| STEP 65 | Remove the stud and fit the bolts to the balancer shaft pinion using a 10mm magnetic socket. Torque pinion to 8 Nm (6 ft lbs), bearing 8 Nm (6 ft lbs). |
| STEP 66 | Install the cover on the timing cover with a new gasket. Torque to 8 Nm (6 ft lbs). |
| STEP 67 | Install the multi-groove belt in the direction of rotation noted earlier, making sure it is positioned correctly over the pulleys. |
| STEP 68 | Install the lower turbocharger delivery pipe. |
| STEP 69 | Close the radiator drain. Conv: Install the chassis reinforcement, front sub frame. |
| STEP 71 | Lubricate the threads sparingly with screw lubricant and install the upper oxygen sensor. Torque to 40 Nm (30 ft lbs). |
| STEP 72 | Plug in and secure the oxygen sensor. |
| STEP 73 | Install the turbocharger heat shield. Torque to 20 Nm (15 ft lbs). |
| STEP 74 | Install the air box and connect the inlet hose, box cover & arr mass sensor |
| STEP 75 | Fill the radiator with coolant to approx. 20 mm above the mark on the expansion tank. |
| STEP 76 | Check for coolant leaks and install the wing lner and spoiler, lower the car, check coolant and top off. |
Pricing for 4 Cyl Water Pumps & Related (Heating & Cooling System) |
