Removal

Removing and Installing Coolant Pump (Engine Installed)




Tools

1. Raise the vehicle at the prescribed jacking points.

2. Open engine compartment lid.

3. Disconnect battery.

4. Remove rear spoiler.

5. Remove bumper with shield.





6. Remove lateral shields.





7. Loosen fastening nuts.





8. Loosen fastening nuts on the turbocharger. Remove the shield





9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two -hexagon socket screws- for this purpose.

CAUTION:
Falling rear muffler.
The rear muffler is loose after the restraining straps are removed. The rear muffler should be held by a second person or supported with a transmission jack.

10. Push restraining straps out of the holder. Push the restraining strap into the recesses of the engine carrier with a screwdriver and move outward.

11. Remove rear mufflers. Two persons can now remove the rear muffler.





12. Undo fastening screw M 6 x 34 on the air cleaner housing.

13. Undo hose clamp between the air cleaner housing and intake manifold.





14. Tilt the complete air cleaner housing 90° upward and then remove from the engine compartment.





15. Pull off the connecting hoses between the charge air coolers and the pressure pipe:
- Unclip the locking clips using a screwdriver and pull off the hose.
- Then clip the locking clips in again.
- Undo the right fastening screw on the refrigerant line.





16. Remove pressure pipe:
- Disconnect connector on the temperature pressure sensor -arrow 4-.
- In order to do this, undo 2 spring band clamps and 1 screw-type hose clamp A/f 7 (-arrow 5- and -arrow 3-, 1 hose clamp not illustrated) and 3 hexagon-head bolts A/f 10 (-arrow 1- and -arrow 2-).
- Pull off vacuum hose to the control valve.





17. Disconnect oxygen sensor plug on the rear closing panel.





18. Disconnect oxygen sensor plug.

19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.





20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously remove the drive belt from the generator.





21. In order to reduce the pressure in the cooling system, carefully open the coolant expansion tank. Undo coolant drain plugs on left and right and collect coolant in a suitable container, so that it can be re-used.

22. Equip drain plugs with new sealing rings and then fasten.
Tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.).

NOTE: When swiveling, make sure not to damage the bellows on the lower joint.





23. Undo stabilizer of the cross member and swivel downwards or disengage.





24. Support the engine-transmission unit:
- In order to do this, fasten special tool (retaining device) 9624/1 on the take-up points of the stabilizer mounts.
- Adjust the pressure screw, until the mounting point is touching the crankcase or the crash support.

25. Separate engine carrier from the engine mounts right and left (a/f 18)





26. Separate engine carrier from the coolant guide housing.

WARNING:
Damage to the console and the oil lines can occur.
- After the engine carrier has been separated the bracket is only held by the oil lines and the O-rings.
- The auxiliary screws can only be removed once the coolant pump has been fastened.





27. Immediately secure the bracket with a shorter auxiliary screw (M10 x 55).





28. Loosen and remove belt guard on the coolant pump.

29. Loosen hose clamp and pull coolant filler hose off the coolant pump.

30. Undo fastening screws of the coolant pump.

31. Remove coolant pump and dispose of seal.