Attention! Proceed with the procedure only after the engine has completely cooled down!
1. Disconnect the negative cable from the battery.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
2. Drain the cooling system (see Chapter Settings and ongoing maintenance). If the coolant has been changed recently, save it for future use (see warning at the beginning of Section Antifreeze - general information).
3. Remove the accessory drive belts (see Chapter Settings and ongoing maintenance).
4. Remove the timing belt.
5. On 4-cylinder models, remove the camshaft timing gear and rear timing belt cover (see Chapter Engine).
6. Remove the mounting bolts and separate the pump from the engine. Try to remember the location of the long bolt(s). Check the back of the rotors for signs of corrosion or missing blades.
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7. Clean the threads of the mounting bolts and bolt holes in the block, completely freeing them from traces of corrosion; if necessary, restore torn threads.
8. Make sure that the new pump matches the old one in size.
9. Remove all traces of sealant and old O-ring material from the mating surface of the engine block.
10. Wipe the mating surfaces of the engine and the new pump with a rag soaked in acetone.
11. Lubricate the bottom and walls of the O-ring groove on the new pump body with RTV sealant, then carefully insert the new O-ring into the groove.
12. Carefully press the pump onto the engine block, screw in a pair of mounting bolts and tighten them only by hand for now. Be sure to lightly coat the threaded portion of the mounting bolts with RTV sealant and make sure the guide pins fit into their mating sockets.
13. Screw in the remaining bolts. Tighten the fasteners to the required torque in several steps (1/4 turn per approach).
Attention! Overtightening of bolts is not allowed under any circumstances due to the risk of deformation of the mating surfaces!
14. Reinstall all components removed to gain access to the pump.
15. Fill the cooling system and remove air locks from it, check the tension of the accessory drive belt(s) (see Chapter Settings and ongoing maintenance). Start the engine and check for signs of coolant leaks.