Water Pump: Service and Repair
Removing and installing coolant pump (engine installed)
Tools
Item Designation of the special tool Explanation
A
B Commercially available;
Removal
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 approximately. 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 ft. lbs.).
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.
Installation
1. Clean sealing surfaces.
2. Install a new seal onto the coolant pump.
Tightening torque: 10 Nm (7.5 ft. lbs.).
3. Install belt guard.
4. Fasten coolant filler hose onto the coolant pump.
5. Remove auxiliary screw again.
6. Fasten engine carrier onto the bracket.
Tightening torque: 65 Nm (48 ft. lbs.).
7. Fasten engine carrier onto the engine mounts (a/f 18).
Tightening torque: 85 Nm (63 ft. lbs.).
8. Remove special tool (retaining device) 9624/1.
9. Fasten stabilizer.
Tightening torque: 25 Nm (18 ft. lbs.).
10. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier. Subsequently tighten the two hexagon socket head bolts slightly.
11. Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts.
Tightening torque: 30 Nm (22 ft. lbs.).
12. Tighten restraining straps on the rear muffler.
Tightening torque: 15 Nm (11 ft. lbs.).
13. Fit heat shields, bumper and rear spoiler.
14. Install drive belt.
15. Check that the installation position of the drive belt on all drive wheels is correct. Check the installation position on the belt pulley from underneath (use light source).
16. Install pressure pipe:
^ Push on vacuum hose to the control valve.
^ Fix connector onto the temperature pressure sensor.
^ Fasten pressure pipe with 2 spring band clamps, 1 screw-type hose clamp and 3 hexagon-head bolts (a/f 10, 10 Nm (7.5 ft. lbs.)).
17. Attach new O rings onto both pressure hoses and coat the O-rings and take-up bores on the pressure pipe with plenty of water.
18. Push the right and left pressure hoses into the pressure pipe, until they audibly engage.
19. Make sure that the pressure hoses have been fitted correctly, by tipping and pulling on the pressure hoses.
20. Install air cleaner housing.
21. Fasten hot film mass air flow meter line:
^ Open omega clip on the left-hand side of the air cleaner housing,
^ Insert electrical line of the hot film mass air flow meter,
^ Close omega clip.
22. Connect battery.
23. Enter radio code.
Note:
^ The cooling system is bled in connection with the Porsche System Tester 2.
^ Select special functions. Menu point.
24. Bleed the cooling system.