Auxiliary Water Pump: Service and Repair

Auxiliary water pump, removing and installing

Notes:
^ All hose connections are secured with clips.
^ Charge air system must be free of leaks.
^ Replace all seals and gaskets

Removing





- Unscrew bolts -arrows- and remove engine cover panels -A...C-.
- Remove bumper.
- Move lock carrier to service position.





- Remove viscous fan (counter-hold with pin wrench 3212).

Note: Viscous fan has left-hand thread: turn in direction indicated.





- Remove air duct -arrows-.





- Pull off brake servo hose -1- at bulkhead.
- Disconnect earth wire from exhaust temperature sender (left side).
- Unscrew exhaust temperature senders from intake manifold (left and right sides) Refer to Fitting locations overview.





- Remove coolant reservoir-arrows and move it clear to the side.

Note: Leave coolant hoses connected.

- Unplug connector from coolant level monitor.
- Remove cover panel from cylinder head cover (cylinder bank 4-6).





- Disconnect hose -2-.





- Pull off hose -1- for vacuum reservoir.
- Unplug connector from air recirculation valve -2-.
- Remove cover above air cleaner.

WARNING: Fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening file connection.





- Disconnect fuel supply line and fuel return line -1- and -2- , and move fuel lines clear.
- Pull hose off EVAP valve -3-.
- Remove cover panel from cylinder head cover (cylinder bank 1-3).





- Pull connectors off injectors -2- on cylinder bank 4...6.





- Unplug connectors from injectors -2- (cylinder bank 1..3).
- Pull off hose -5- going to turbocharger intake side.





- Unclip solenoid valve for charge pressure control -1-.
- Pull connector off EVAP valve -2-.





- Remove pressure pipes -1-.

Note: Watch position of retaining strips -2-.





- Pull connector off throttle unit -1-.
- Pull connector off charge air sensor -2-.
- Pull off crankcase breather -3-.
- Pull connector off intake air temperature sender-4-.
- Unbolt intake manifold using special tool 3249.
- Pull off connector for auxiliary water pump.
- Pinch off water hoses using clamps 3094 for auxiliary water pump.
- Remove auxiliary water pump.

Installing
Install in the opposite order to removing. When installing, note the points:
- Install lock carrier in normal position.
- Install bumper.

Tightening Torques (Part 4 Of 4):

Tightening torques