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.
- 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).

- 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 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.

- Install ribbed belt and tensioning element.
- Fill up with coolant.

Tightening torque