Water Pump: Service and Repair

Coolant Pump, Removing And Installing

Note: Always replace seals and gaskets.

Removing





- Remove engine cover.
- Drain cooling system.






- Remove center and right-hand sections of noise insulation -arrows-.
- Removing ribbed belt and tensioning element Page 13-1 .
- Disconnect vacuum hose from activated charcoal filter and from throttle valve connection.






- Remove coolant expansion tank (see left-hand arrows) together with hoses.
- Unbolt power steering reservoir (see right-hand arrow). Do not disconnect the hoses.
- Remove toothed belt guards (upper and center) Page 13-13 .






- Set crankshaft to markings for TDC of No. 1 cylinder -arrows- by turning central bolt on crankshaft sprocket in direction of rotation.






- Screw M5x55 stud -1- into toothed belt tensioning element. Screw hex nut -2- onto stud -1- using a large washer -3-.
- Tension pressure piston of tensioning element only until it can be secured with a locking pin (e.g. from lifting appliance 2024 A) -arrow-.

Note: If it is not possible to insert the locking pin, carefully tension the pressure piston of the tensioning element just enough to allow the toothed belt to be removed.

- Take toothed belt off camshaft sprocket.

Note: The vibration damper and bottom toothed belt guard do not have to be removed. The toothed belt should be left in position on the crankshaft sprocket. Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.






- Remove coolant pump securing bolts -1- and remove coolant pump -2-.

Installing
Installation is carried out in the reverse order, when doing this, please note the following:
- Clean and smooth down sealing surface for O-ring as required.
- Moisten new O-ring with coolant G 012 A8 D.
- Install coolant pump. Installation position: plug in housing faces downward.
- Install toothed belt (adjust valve timing).

Note: Follow all the instructions on removing and installing the toothed belt Page 13-10 .

- Installing ribbed belt and tensioning element Page 13-1 .
- Fill up with coolant Page 19-6 .

Tightening Torque
Component Torque
Coolant pump to cylinder block 15 Nm.