Removing and installing coolant pump

The coolant pump can only be repaired on the 1.6 L engine; on the other engines the entire pump must be replaced. If the shaft seal is defective, coolant runs down the engine block, mainly when the engine is running.

• Disconnect the battery negative (-) cable. Warning: this erases electronic memories, such as engine operating values. Observe the notes in the chapter "Remove and install battery".

• Drain and collect the coolant, see page 71.

• Remove the poly-V belt and timing belt, see page 22.

• Hold the camshaft sprocket from the front with a screwdriver. Unscrew and remove the camshaft sprocket. If necessary, drive it off carefully with light blows from a rubber mallet.

• Unscrew the coolant pump -arrows-, and remove the pump with its O-ring from the engine block.

• First clean the sealing surfaces on the cylinder head with a sharp blade, then wipe them with a dry cloth to remove gasket residue and other deposits.

• Fit the new pump with a new O-ring. Do not overtighten the bolts; torque 25 N·m.

• Fit the camshaft sprocket so that the lug on the sprocket engages the recess in the camshaft. Tighten the mounting bolt to 120 N·m, holding the camshaft sprocket counter with a screwdriver.

• Install the timing belt, see page 22.

• Disconnect the negative (-) battery terminal. Set the clock and enter the radio anti-theft code.

• Run the engine until warm. Then park the vehicle on a dry surface and check the cooling system for leaks.

• Disconnect the battery negative (-) cable. Warning: this erases electronic memories, such as engine operating values. Observe the notes in the chapter "Remove and install battery".

• Drain and collect the coolant, see page 71.

• Remove the poly-V belt and timing belt, see page 22.

• Lock the intake camshaft sprocket from the front with a screwdriver. Unscrew and remove the camshaft sprocket; if necessary, tap it off with light blows from a rubber mallet. The exhaust camshaft sprocket remains installed.

• Unscrew the side covers.

• Unscrew the coolant pump -arrows-. Remove the pump with its seal ring from the engine block.

• Clean the sealing surface on the cylinder head first with a sharp blade, then wipe it with a dry cloth to remove gasket residue and other deposits.

• Fit the new pump with a new O-ring. Do not overtighten the bolts; torque 25 N·m.

• Fit the camshaft sprocket so that the lug on the sprocket engages the recess in the camshaft. Tighten the mounting bolt to 120 N·m, holding the camshaft sprocket counter with a screwdriver.

• Install the timing belt and V-ribbed belt, see page 22.

• Disconnect the negative (-) battery terminal. Set the clock and enter the radio anti-theft code.

• Run the engine until warm. Then park the vehicle on a dry surface and check the cooling system for leaks.

• Disconnect the battery negative (-) cable. Warning: this erases electronic memories, such as engine operating values. Observe the notes in the chapter "Remove and install battery".

• Drain and collect the coolant, see page 71.

• The coolant pump is located on the side of the engine block. It is driven by the drive belt, which also drives the alternator. Remove the drive belt, see page 58.

• If the coolant pump is difficult to access, unscrew the power steering pump from its bracket -arrows- and move it aside with the lines still connected.

• Unscrew the alternator bracket at the top of the coolant pump.

• Unscrew the lower alternator bracket -arrow-. Swing the alternator aside to access the coolant pump.

• Unscrew the coolant pipe from the coolant pump, bolts -1-.

• Unscrew the 4 mounting bolts -2- for the coolant pump on the engine block. Remove the coolant pump with its flat gasket.

• Carefully remove gasket residue with a scraper.

1. 1

   Pump cover

2. 2

   Spacer bushing

3. 3

   Safety screw

4. 4

   Nuts for pump housing

5. 5

   Retaining bracket,

6. 6

   Pump housing

7. 7

   Pump impeller

8. 8

   Seal ring

9. 9

   Circlip

10. 10

    Flat gasket

11. 11

    Thrust washer

12. 12

    Seal ring

13. 13

    Ball bearing

14. 14

    V-belt pulley

15. 15

    Pump shaft

• If necessary, disassemble the coolant pump. Note: a suitable press and puller are required for this.

• Unscrew the pump cover.

• Pull the pump impeller off the shaft. Fiat workshops use puller A.40026 for this.

• Unscrew the safety screw.

• Press the pump shaft together with bearings and pulley out of the pump housing.

• Press the pulley off the pump shaft.

• If defective, remove the oil seal. To do so, drive out the seal ring with a brass drift. Press the new seal ring on with a suitable tube.

• Replace defective parts. When reassembling, note that the impeller should have a clearance of 0.3 to 1.1 mm from the pump cover; check this with a feeler gauge. The pump must also turn easily by hand.

• Replace the flat gasket between pump and engine block.

  The sealing surfaces must be clean and dry.

• Tighten the coolant pump to 25 N·m.

• Tighten the coolant pipe with a new O-ring seal.

• Bolt the alternator to its bracket.

• Install the power steering pump and the drive belt, see page 164.

• Refill the coolant. See page 71.

• Disconnect the negative (-) battery terminal. Set the clock and enter the radio anti-theft code.

• After the test drive, check the cooling system for leaks.