Ok, The job wasn't as difficult as I thought. just time consuming. It took me the best part of a day (9:00am-4:00pm)
You'll need a Metric tool set, complete with spanners both open and closed, a socket set comprising of Torsion, allen key and standard. All ranging from 8mm to 20mm.
You'll also need some axel stands as your cars going to be jacked up for a while and it'd probably be safest to secure it. You'll need to get in the car or have someone get in the car to compress the brake pedal later on to, this will be whilst your underneath the car so for piece of mind...
There isn't a great deal of space to work with so taking as much easyily removable parts from the drivers side of engine bay will help, First things first
1. To gain space, unfasten the Water and Powersteering fluid tanks from the bolts that hold them. (8mm-10mm bolts)
no need to completely disconect them, just move them to one side. over the front of the car or top of the engine.
2. Loosen the bolts to your drivers side wheel, Jack the car up on the axel stands and remove the wheel, unscrew the plastic covers behind it.
3. whilst your down there, remove the bottom plastic cover from under the engine. the one covering the V belt. there should be three bolts, probably 10mm.
4. Remove the top cover from the plastic cover on the drivers side of the engine uncovering the twin cam wheels.
5. Remove the Water Pump Wheel. Undo the four bolts holding the wheel to the water pump unit. Lightly tap the wheel off, The metal is quite soft and damages easily so remove with care.
5.1 Remove the Wheel from the bottom. placing the bolt back in after. I'll explain why later. to undo this bolt at the bottom, you'll need to put the car into 5th gear. and suppress the brake hard.
6. Remove the bottom half of the plastic cam belt cover, three bolts should be securing it, expose the bottom of the cam belt and wheels. also the water pump below that.
*** When you get to this part TAKE EXTREME CARE not to move the twin cam wheel at the top of the engine or the wheel is the bottom of the engine, if that happens and you don't notice it, its likely you'll ruin the engine on starting.
7. Loosen the bolt on the tension wheel, this wheel should be a smooth wheel.
8. Remove the Cam Belt (making 100% sure not to rotate any of the wheels individually.) to gain access to the water pump.
9. Place a bucket underneath the water pump unless you want the remaining engine water with the coolant going everywhere.
10. Remove the water bump from the engine. It should be secure with 4 bolts 8-10mm.
NOTE: you may not be able to remove the pump with out first undoing the clip securing the hose from the pump to the radiator.
11. After the engine has drained, whipe away any excess water from the place the old gasket used to be.
12. Remove the two wheels from the old water pump using a Torsion socet.
13. Put the two wheels from the old water pump onto your new water pump.
14. Attach the new water pump to the Hose from the radiator.
15. Attach the new water pump to the engine with the gasket correctly in place. Tighten the bolts securly, do so diagonly.
16. Attach the cam belt. Take care when putting it back on not to move the position of the cam wheels. you can do this by first feeding the bottom of the belt down to the bottom wheel, then, holding the belt in both hands, both hands together in fists. knuckles together, with the belt running over the top of your hand and your thumbs holding the belt tooth side to your index fingure knuckles, run your hands apart and with tension on the belt, bring it down over the top of the cams. follow round both side, the teeth should settle in the groves. follow the belt down both sides to the cog at the bottom.
17. Tighten the belt to a point where its not tort, just that it gives a little.
18. Make sure that everything is tightend properly.
19. For this part, You'll need your mate back again to put a foot on the brake whils the car is in gear. using the bolt at the bottom, using a spanner, rotate the cog and listen intently to the engine, if the engine makes a knock then doesn't rotate any further, the CAMs have been moved sometime you where working on the engine and you will need to realign them.
If the engine compress's thats the sound of sucess and you can carry on reassembling the engine in the revers order you took it apart.
20. Once the engine is reasembelled. you can fill the water tank back up using a 50/50 coolant/water mix.
Make sure you don't over fill it, although it will require a couple of fills to the max line to fill the engine aswell and the tank and rest of system.
take it for a short test drive. You should have just sucessfully changed your water pump.
Max
March 2006
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