9-3 1999

Removal & Installation

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2.0L & 2.3L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Center air deflector
     
    Right front wheel
     
    Front section of the inner fender panel
     
    Expansion tank, with its hoses and electrical connector
     

  8.  
  9. Pull hard on the drive belt and lock the tensioner.

    Water pump and A/C compressor belt
     

  10.  
  11. Place protective covers on the engine oil cooler and upper radiator crossmember.
    WARNING
    Use care not to damage the O 2 S sensor.



    A/C compressor electrical connector
     
    A/C compressor with the lines attached and position it to the side
     
    A/C compressor bracket
     
    Coolant hoses to water pump
     
    Oxygen O 2 S sensor wire from the clips
     
    Coolant pipe from the turbocharger
     
    Coolant pipe from water pump
     
    Three bolts attaching the water pump to the timing cover
     
    Water pump by prying first at the sleeve in the cylinder block, then around the rest of the pump
     



    Water pump pulley then take the pump out of its housing
     

  12.  

To install:

  1. Clean the sealing surfaces and use a new gasket.
  2.  
  3. Install or connect the following:

    Water pump in the housing
     
    Water pump pulley and torque the bolts to 72 inch lbs. (8 Nm)
     
    Water pump to cylinder head sleeve and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Coolant pipe to the water pump
     
    Coolant pipe to the turbocharger
     
    O 2 S sensor wire in the clips
     
    Coolant hoses to water pump
     
    A/C compressor bracket
     
    A/C compressor
     
    Compressor electrical connector
     

  4.  
  5. Protective covers from the engine oil cooler and the upper radiator crossmember may now be removed.

    Water pump belt. Pull on it firmly and remove the locking pin from the tensioner. Check for proper belt alignment and tension.
     
    Coolant hoses and electrical connector to expansion tank
     
    The expansion tank
     
    Center air deflector
     
    Front section of the inner fender panel
     
    Right front wheel
     
    Negative battery cable
     

  6.  
  7. Properly fill the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

 
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