Coolant pump, removing and installing

NOTE: Always replace seals and gaskets.

Removing

Fig 1: Remove Engine Cover Panel Above Cylinder Head.

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Remove engine cover.
Drain cooling system. Refer to Draining

Fig 2: Removing Noise Insulation Panels (Center, Left And Right)

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Remove center and right-hand sections of noise insulation (arrows).
Removing ribbed belt and tensioning element. Refer to Ribbed belt, removing and installing .
Disconnect vacuum hose from activated charcoal filter and from throttle valve connection.

Fig 3: Detaching Coolant Expansion Tank And Power Steering Reservoir

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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). Refer to Toothed belt, removing and installing .

Fig 4: Setting Crankshaft To Markings For TDC Of No. 1 Cylinder

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

Fig 5: Screwing Stud Into Toothed Belt Tensioning Element & Hex Nut Onto Stud Using Large Washer

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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.

Fig 6: Identifying Coolant Pump & Securing Bolts

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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). Refer to Installing (adjusting valve timing)

NOTE: Follow all the instructions on removing and installing the toothed belt. Refer to Toothed belt, removing and installing .

Installing ribbed belt and tensioning element. Refer to Ribbed belt, removing and installing .
Fill up with coolant. Refer to Filling .

Tightening torque

Component	Nm
Coolant pump to cylinder block	15