Removal

NOTE: The method described applies to a car equipped with water-cooled turbo, intercooler, AC, automatic transmission, catalytic converter, two-stage cooling fan and automatic belt tensioner. The procedure will obviously need to be adapted as appropriate to suit cars to different specifications.

1. Disconnect the negative (-) battery lead and cover the terminal pole on the battery.





2. Install locking segment 8393993 to the flywheel.





3. Remove the bracket for the dipstick tube and bend the tube out of the way. Remove the screw securing the coolant pipe (above the knock detector).








4. Raise the car and drain the engine oil and coolant.





5. Remove the RH front wheel and front section of the wing liner





6. Slacken the AC drive belt by loosening the locknut. Remove the belt.





7. Using a swivel socket wrench, push down on the idler-wheel pulley to slacken the multi-groove belt.





8. Ease the belt off the water-pump pulley and then release the idler-wheel pulley.





9. Lift the belt off the remaining pulleys and remove it.





10. Remove the two bolts and remove the belt-tensioner spring unit.

NOTE: Notice that the top bolt is longer than the lower one and also the orientation of the unit.





11. Remove the idler-wheel pulley centre-bolt, followed by the backplate and idler-wheel pulley.





12. Remove the crankshaft pulley.





13. Remove the coolant pipe securing bolt.





14. Remove the clips for the oil-cooler oil pipes.





15. Remove the securing bolts for the steady bar between the steering servo pump and the timing cover. Notice the non-captive nut on the bolt.





16. Remove the top securing bolt for the alternator and the two securing bolts for the steering servo pump. Lift off the bracket and steady bar.





17. Slacken off the alternator pivot bolt (socket head) and swivel the alternator out of the way. Remove the four securing bolts for the bracket for the alternator and steering servo pump. Lift out the bracket.





18. Place a suitable receptacle underneath the oil filter and remove all dirt from the pipe fittings. Remove the pipe fittings, withdraw the pipes and move them aside.





19. Remove the water-pump pulley.





20. Withdraw the coolant pipe from the coolant pump and move the pipe well clear of the timing cover.

CAUTION: Take care not to damage the cylinder-head gasket.

NOTE: When removing the timing cover, notice that the bolts are of different lengths. Note the bolts in the sump (two) and cylinder head (two).

21. Remove all securing bolts for the timing cover. Lift off the timing cover complete with oil pump.





22. Remove the gaskets that seal with the flange on the block. Carefully remove all traces of gasket from the flange. Also remove all traces of silicone sealant from the sump gasket. Clean the flanges using industrial petrol (benzine).
23. Remove the pump from the timing cover.