Water Pump Replacement Opel Agila B

Remove

1. 1. Disconnect battery negative lead • Release nut
2. 2. Release pulley (1) from water pump • Release 4x bolt (2); do not remove at this stage

3. 3. Remove cap from radiator
4. 4. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

5. 5. Drain cooling system • Place collecting container below • Open radiator drain plug (1) • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container

6. 6. Remove splash panel from vehicle, right side • Remove 2x bolt (1), 4x clip (2)

7. 7. For vehicles with air conditioning, remove compressor ribbed V-belt • Release bolt (1) • Rotate bolt (2) anti-clockwise until tension is released, then remove ribbed V-belt

8. 8. Remove ribbed V-belt • Release 2x bolt (1, 2) • Rotate bolt (3) anti-clockwise until tension is released, then remove ribbed V-belt

9. 9. Lower vehicle
10. 10. Remove pulley (1) from water pump • Remove 4x bolt (2)

11. 11. Remove bracket from water pump and alternator • Remove bolt (1), 2x nut (2)

12. 12. Remove water pump (1) from engine • Place collecting container below • Remove 4x bolt (2)

Install

13. 13. Clean mating surface on engine
14. 14. Apply water tight sealant (1) to new water pump – see “Sealants, Adhesives and Lubricants” • Dimension X = 3 mm • Dimension Y = 2 mm

15. 15. Install water pump (1) to engine • Install 4x bolt (2) 25 Nm

16. 16. Install bracket to water pump and alternator • Install 2x nut (2) 25 Nm • Install bolt (1); do not tighten at this stage

17. 17. Install pulley (1) to water pump • Install 4x bolt (2); do not tighten at this stage

18. 18. Raise vehicle
19. 19. Install ribbed V-belt • Rotate bolt (3) clockwise until deflection of belt when thumb pressure applied is 4.0 mm - 4.5 mm at position arrowed • Secure bolt (1) 25 Nm • Secure bolt (2) 50 Nm

Note. If new belt is installed, deflection is 3.0 mm - 3.5 mm .

20. 20. For vehicles with air conditioning, install compressor ribbed V-belt • Rotate bolt (2) clockwise until deflection of belt when thumb pressure applied is 7.0 mm - 8.0 mm at position arrowed • Secure bolt (1)

Note. If new belt is installed, deflection is 6.0 mm - 7.0 mm .

21. 21. Install splash panel to vehicle, right side • Install 4x clip (2), 2x bolt (1)

22. 22. Lower vehicle
23. 23. Secure pulley (1) to water pump • Secure 4x bolt (2) 11 Nm

24. 24. Connect battery negative lead • Secure nut 11 Nm
25. 25. Remove coolant expansion tank (1) from battery tray • Disconnect overflow hose from radiator – Release clip • Install 2x new blanking plug • Slide off

26. 26. Remove cap from coolant expansion tank

Important. Observe the relevant environmental regulations when disposing of used coolant.

27. 27. Drain any fluid from coolant expansion tank • Clean inside of coolant expansion tank; flush it well with clean water and drain
28. 28. Install coolant expansion tank (1) to battery tray • Slide on • Remove 2x blanking plug • Connect overflow hose to radiator – Secure clip

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

29. 29. Fill coolant expansion tank with new coolant fluid up to maximum level mark
30. 30. Install cap to coolant expansion tank
31. 31. Fill radiator with new coolant fluid up to bottom of radiator filler neck
32. 32. Install cap to radiator
33. 33. Start engine and allow it to run at idle speed until thermostat opens

Note. Cooling system bleeds itself automatically during the warm-up phase.

34. 34. Switch off engine
35. 35. Check and correct coolant fluid level
36. 36. Program all volatile memories – see operation “Program Volatile Memories”