Water Pump: Service and Repair

Coolant Pump, Removing and Installing

Note: Always replace seals and gaskets.

Removing




- Remove engine cover.




- Disconnect air duct at bottom of right - hand longitudinal member (air duct leads to charge air cooler).
- Drain coolant system. Service and Repair




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




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




- 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 hexagonal nut -2- onto stud -1- using 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.

- Remove toothed belt from camshaft sprocket.

Notes:
- 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.

Vehicles with air conditioning:
- Remove lower air duct.

All models



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


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

Notes: Follow all the instructions on removing and installing the toothed belt.

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


Tightening torque