Opel Corsa B 1993–2000 Service and Repair Manual: Water pump - removal and refitting

Removal

1. Drain the cooling system then disconnect the battery earth lead. Proceed as described under the relevant sub-heading.

1.2 litre models

2. Remove the auxiliary drivebelt.

3. Slacken the hose clips and disconnect the three hoses from the pump

4. Remove the six retaining bolts and carefully pull the pump off the head (see illustration).

Recover the gasket.

Removing the water pump - 1.2 litre model

5. If a new pump is being fitted, unbolt and transfer the pump pulley. Transfer the thermostat also, or fit a new one if the old one has seen much service.

6. Before refitting the water pump clean away all traces of old gasket from the pump and cylinder head mating faces.

7. Apply a little grease to a new gasket and place it in position on the pump. Refit the pump and secure the unit with the six bolts tightened progressively to the specified torque.

8. Refit the three hoses and tighten the clips securely. Refit the drivebelt and adjust the tension, as described in Section 9. Finally, refill the cooling system and reconnect the battery.

1.3, 1.4, 1.6, 1.8 and 2.0 litre 8-valve models

9. Remove the camshaft toothed belt and the toothed belt backplate.

10. Remove the three securing bolts and withdraw the water pump (see illustration).

Note that it may be necessary to remove the alternator completely to provide enough room to remove the pump from the engine bay.

Removing the water pump - 1.8 litre model shown

2.0 litre 16-valve models

11. Removing the following components.

1. Camshaft toothed belt.
2. Camshaft cover.
3. Camshaft sprockets.
4. Toothed belt tensioner and idler rollers.
5. Crankshaft sprocket.
6. Toothed belt backplate.

12. Remove the three bolts which secure the water pump to the block. Remove the pump and clean the recess in the block.

Refitting

1.2 litre models

13. If a new pump is being fitted, unbolt and transfer the pump pulley. Transfer the thermostat also, or fit a new one if the old one has seen much service.

14. Before refitting the water pump clean away all traces of old gasket from the pump and cylinder head mating faces.

15. Apply a little grease to a new gasket and place it in position on the pump. Refit the pump and secure the unit with the six bolts tightened progressively to the specified torque.

16. Refit the three hoses and tighten the clips securely. On completion, refit the drivebelt and refill the cooling system.

1.3, 1.4, 1.6, 1.8 and 2.0 litre 8-valve models

17. Refitting is the reverse of removal, noting the following points.

1. Fit a new sealing ring to the pump (see illustration).
2. Ensure that the pump and its recess are clean and dry and coat the sealing ring and cylinder block mating surface with silicone grease or petroleum jelly. This will prevent contact corrosion between the pump and the block, and make things easier if the pump has to be moved for adjustment of the camshaft toothed belt.
3. Fit the camshaft toothed belt and tension, and tighten the pump bolts to the specified torque.
4. On completion refill the cooling system and adjust the alternator drivebelt.

Fitting a new sealing ring to the pump

2.0 litre 16-valve models

18. Refitting is the reverse of removal using a new sealing ring. Tighten the pump mounting bolts to the specified torque then refit all disturbed components. On completion refill the system.