Removing and Installing Coolant Pump

Removing and installing coolant pump














Special tools








Coolant pump components

Removing coolant pump

Note:
^ The engine cooling system is filled at the factory with a coolant that does not need to be changed.
^ The coolant need only be replaced when contaminated, e.g. oil mixed with coolant.

1. Remove the front engine guard.
2. Remove underbody cover.
3. Remove the sheetmetal brace under the radiator. To do this, loosen the 4 fastening screws.





4. Drain cooling system. Remove the drain plug from the radiator, drain the coolant into a container and dispose of it according to the applicable national laws if no longer required. Then close the drain outlet with a new sealing plug.
5. Install the sheetmetal brace under the radiator. Tighten the 4 fastening screws to 23 Nm (17 ft. lbs.).





6. Remove the radiator frame.





7. Pull the cover of the throttle body vertically upwards.





8. Separate the electrical connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull off. Unclip the cable from the sheetmetal holder.





9. Release the fastening bolts on the throttle body. To do this, turn the right-hand bolt 45° counterclockwise, the left bolt 45° clockwise.





10. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.
11. Pull off the Y pipe from the throttle body.





12. Disconnect the air flow sensors. To do this, undo the hose clamps on the left and right on the bellows and pull the bellows off the air flow sensors.





13. Remove the vacuum line on the Y pipe. To do this, press the button and disconnect the vacuum line.





14. Remove the throttle adjuster. Loosen the 4 fastening screws.

Note: To ease removal, spray the pulley from the rear side with an anti-corrosion agent.





15. Unscrew the 3 fastening screws on the coolant pump pulley. Wrench size T 40.

Warning: Risk of damage! Never remove a drive belt when it is hot.





16. Remove the drive belt from the coolant pump pulley. Mark the direction of running of the drive belt with chalk.





17. Use an open-end wrench (a/f 30) to turn the belt tensioner clockwise and, at the same time, remove the drive belt from the tensioning roller. Relieve the belt tensioner carefully. Remove the drive belt from the coolant pump.

Warning: Risk of damage!
^ The pulleys on engine accessories are made of plastic. Do not use damaged pulleys.
^ The pulley is sensitive to impacts.
^ Do not prize off the pulley with a screwdriver.





18. Remove the 3 loosened fastening screws on the pulley and remove the pulley.





19. Remove the 8 fastening screws on the coolant pump and remove the pump. If the pump is stuck, loosen it by gently tapping with a plastic hammer.





Loosening the coolant pump with a plastic hammer

Installing coolant pump





1. Mount new sheetmetal seal on the coolant pump. Slide the new sheetmetal seal over the dowel pins.





2. Tighten the 8 fastening screws with 10 Nm (7.5 ft. lbs.). Mount the sheetmetal holder for the cable duct using the 2 upper fastening screws.
3. Fit the pulley on the coolant pump. Screw in the 3 fastening screws by hand.





4. Mount the drive belt. To do this, turn the belt tensioner clockwise and thread the drive belt around all the pulleys. Then carefully relieve the tensioning roller.
5. Check whether the drive belt is correctly installed.





6. Tighten the 3 fastening screws to 23 Nm (17 ft. lbs.).





7. Fit the throttle adjuster with new seal. Tightening torque of the four screws 23 Nm (17 ft. lbs.)
8. Install the radiator frame.





9. Attach the vacuum line to the underside of the Y pipe.





10. Slide the bellows onto the air flow sensors and tighten the hose clamps.





11. Slide the Y pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn the right bolt 45° clockwise and the left bolt 45° counterclockwise.





12. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.





13. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must be felt to engage.
14. Fill and bleed the cooler circuit.





Tightening torques