Coolant pump (B235R)
Coolant pump (B235R) |
1. |
Open the expansion tank's pressure cap to release system pressure.
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2. |
Raise the car.
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3. |
Connect a hose to the system's drain plug and drain the coolant into a suitable receptacle.
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4. |
Detach the coolant pipe from the turbocharger.
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5. |
Check that the cooling system's drain plug is closed and lower the car to the floor.
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6. |
Remove the air hose between the air collector casing and the turbocharger's intake pipe.
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7. |
Snip the 2 cable ties securing the engine's main wiring harness. Relieve the belt tensioner of tension and lock it using a drill bit or the like.
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8. |
Lift the belt off the power steering pump and coolant pump pulleys.
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9. |
Remove the cover over the throttle body.
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10. |
Detach the crankcase ventilation pipe from the turbo's intake pipe and camshaft cover. Move the pipe to aside.
Collect the copper seals. |
11. |
Unplug the solenoid valve's connector.
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12. |
Detach the solenoid valve hoses.
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13. |
Remove the engine lifting eye.
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14. |
Remove the bypass pipe with valve. Collect the O-ring from the connection to the turbocharger's intake pipe.
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15. |
Remove the heat shield over the exhaust manifold.
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16. |
Detach the venting hose from the T-connection.
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17. |
Remove the turbocharger's intake pipe, plug the turbo.
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18. |
Remove the power steering pump's bolt on the right-hand side.
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19. |
Remove the power steering pump's bolt on the left-hand side.
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20. |
Angle up the power steering pump and remove the lower bolt and the 2 upper bolts.
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21. |
Move the power steering pump and bracket aside and secure with a cable tie or similar.
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22. |
Undo the hose clips and detach the hoses from the coolant pump's inlet.
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23. |
Detach the two longitudinal coolant pipes from the cylinder block.
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24. |
Disconnect the coolant pipes from the coolant pump, collect the O-rings and move the pipes aside.
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25. |
Loosen the coolant pump slightly.
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26. |
Detach the coolant pipe from the coolant pump. Collect the seals.
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27. |
Undo the coolant pump's 3 retaining bolts.
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28. |
Carefully wiggle the coolant pump away from the mounting and from its connecting piece in the cylinder block.
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29. |
Remove the connecting piece from the cylinder block, check its seals and change as necessary.
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To fit |
1. |
Fit the connecting piece to the cylinder block. Coat the seals with Gleitmo 805, part no. 30 06 442.
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2. |
Fit the coolant pump in place but do not tighten it.
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3. |
Position the coolant pipe between the coolant pump and turbocharger. Use new washers and seals.
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4. |
Tighten the coolant pipe to the coolant pump.
Tightening torque: 20 Nm |
5. |
Bring the two transverse coolant pipes up to the coolant pump, using new O-rings coated with non-acidic vaseline, part no. 30 06 665 or the like.
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6. |
Tighten the coolant pump, 3 bolts.
Tightening torque: 22 Nm (16.2 lbf ft) |
7. |
Tighten the two transverse coolant pipes.
Tightening torque: 10 Nm (7.4 lbf ft) |
8. |
Fit the power steering pump and bracket.
Tightening torque: 24 Nm (17.7 lbf ft) |
9. |
Fit hoses and hose clips on the coolant pump's inlet.
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10. |
Remove the plug from the turbocharger's air intake. Inspect the O-ring and coat it with non-acidic vaseline, part no. 30 06 665, or the equivalent.
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11. |
Fit the turbocharger's intake pipe but do not tighten the V-clamp.
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12. |
Fit the solenoid valve on the engine lifting eye.
Connect the hoses to the solenoid valve. Note the markings on the hoses and the connection. |
13. |
Fit the engine lifting eye.
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14. |
Tighten the turbocharger's intake pipe, V-clamp.
Tightening torque: 3 Nm (2.2 lbf ft) |
15. |
Connect the venting hose to the T-connection.
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16. |
Fit the heat shield over the exhaust manifold.
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17. |
Fit the bypass pipe and valve, using a new O-ring for the connection to the turbocharger's intake pipe.
Tightening torque: 8 Nm (5.9 lbf ft) |
18. |
Spray the solenoid valve's connector with Kontakt 61, part no. 30 04 520, and plug it in.
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19. |
Fit the crankcase ventilation pipe to the turbocharger's intake pipe. Use new copper seals.
Tightening torque: 24 Nm (17.7 lbf ft) Fasten the crankcase ventilation pipe to the camshaft cover, clip. |
20. |
Fit the throttle body's cover.
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21. |
Raise the car and fit the coolant line to the turbocharger.
Tightening torque: 25 Nm (18.4 lbf ft) |
22. |
From underneath, check that the multigroove V-belt is correctly fitted round all pulleys.
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23. |
Check that the cooling system's drain plug is closed.
Lower the car to the floor. |
24. |
Relieve the belt tensioner of tension by means of a flexible handle and remove the locking piece (drill bit or the like). Make sure that the belt is fitted correctly and carefully remove the flexible handle.
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25. |
Secure the engine's main wiring harness with cable ties.
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26. |
Fit the air hose between the air collector casing and the turbocharger's intake pipe.
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27. |
Fill up with coolant. For the correct mixture, see “Cooling system“.
Close the filler cap. |
28. |
Fill up and bleed the system as follows:
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Fill the system up to the MAX level, fit the pressure cap, start the engine and warm it up at varying rpm until the radiator fan starts.
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Switch off the engine and top up as necessary to the MAX level.
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29. |
Raise the car to check for oil or coolant leakage.
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30. |
Lower the car and top up the coolant and/or oil as necessary.
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