Coolant pump (B235R, B205L/R)
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Coolant pump (B235R, B205L/R)
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1.
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Open the expansion tank pressure cap to release system pressure.
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3.
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Connect a hose to the system drain plug and drain the coolant into a suitable receptacle.
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4.
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Detach the coolant pipe from the turbocharger.
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5.
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Close the system drain plug and lower the car.
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6.
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Remove the air hose between the air collector casing and the turbocharger intake pipe.
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7.
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Cut the 2 cable ties securing the main engine cables. Relieve the strain on the belt tensioner with a ratchet handle and secure the belt tensioner with a 3.5 mm drill or similar.
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8.
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Lift the belt off the power steering pump and coolant pump pulleys.
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9.
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Remove the top engine cover.
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10.
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Detach the crankcase ventilation pipe from the turbo inlet pipe and camshaft cover. Bend the pipe to one side.
Keep seals and washers safe.
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11.
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Unplug the solenoid valve's connector.
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12.
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Detach the solenoid valve hoses.
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13.
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Remove the engine lifting eye.
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14.
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Remove the bypass pipe with valve. Keep the O-ring from the connection to the turbocharger intake pipe.
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15.
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Remove the heat shield over the exhaust manifold.
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16.
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Detach the venting hose from the T-connection.
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17.
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Remove the turbocharger's intake pipe, plug the turbo.
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18.
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Remove the power steering servo pump bolt on the right-hand side behind the belt pulley.
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19.
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Undo the upper power steering servo pump bolt.
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20.
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Lift up the power steering servo pump and remove the lower bolt and the 2 upper bolts on the bracket.
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21.
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Move the power steering pump and bracket aside and secure with a cable tie or similar.
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22.
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Undo the hose clips and detach the hoses from the coolant pump inlet.
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23.
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Detach the two longitudinal coolant pipes from the cylinder block.
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24.
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Disconnect the coolant pipes from the coolant pump, keep the O-rings and move the pipes aside.
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25.
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Loosen the coolant pump slightly.
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26.
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Detach the coolant pipe from the coolant pump. keep the seals.
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27.
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Undo the coolant pump's 3 retaining bolts.
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28.
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Carefully wiggle the coolant pump away from the mounting and from its connecting piece in the cylinder block.
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29.
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Remove the connecting piece from the cylinder block, check its seals and change as necessary.
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1.
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Fit the connecting piece to the cylinder block. Coat the seals with Gleitmo 805, part no. 30 06 442.
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2.
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Fit the coolant pump in place but do not tighten it.
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3.
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Position the coolant pipe between the coolant pump and turbocharger. Use new washers and seals.
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4.
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Tighten the coolant pipe to the coolant pump.
Tightening torque: 20 Nm
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5.
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Bring the two transverse coolant pipes up to the coolant pump, use new O-rings coated with non-acidic vaseline, part no. 30 06 665 or the like.
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6.
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Tighten the coolant pump, 3 bolts.
Tightening torque: 22 Nm (16.2 lbf ft)
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7.
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Tighten the two transverse coolant pipes.
Tightening torque: 10 Nm (7.4 lbf ft)
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8.
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Fit the power steering pump and bracket.
Tightening torque: 24 Nm (17.7 lbf ft)
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9.
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Fit hoses and hose clips on the coolant pump inlet.
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10.
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Remove the plug from the turbocharger 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.
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Fit the turbocharger inlet pipe but do not tighten the V-clamp.
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12.
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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.
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13.
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Fit the engine lifting eye.
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14.
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Tighten the turbocharger's intake pipe, V-clamp.
Tightening torque: 3 Nm (2.2 lbf ft)
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15.
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Connect the venting hose to the T-connection.
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16.
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Fit the heat shield over the exhaust manifold.
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17.
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Fit the bypass pipe and valve, use a new O-ring for the connection to the turbocharger inlet pipe.
Tightening torque: 8 Nm (5.9 lbf ft)
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18.
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Spray the solenoid valve connector with Kontakt 61, part no. 30 04 520, and plug it in.
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19.
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Fit the crankcase ventilation pipe to the turbocharger intake pipe. Use new copper seals.
Tightening torque: 24 Nm (17.7 lbf ft)
Fasten the crankcase ventilation pipe to the camshaft cover, clip.
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20.
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Fit the throttle body's cover.
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21.
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Raise the car and fit the coolant line to the turbocharger.
Tightening torque: 25 Nm (18.4 lbf ft)
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22.
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From underneath, check that the multigroove V-belt is correctly fitted round all pulleys.
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23.
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Check that the cooling system's drain plug is closed.
Lower the car to the floor.
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24.
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Relieve the tension on the belt tensioner with a ratchet handle and remove the catch. Make sure the belt is positioned correctly and carefully release the ratchet handle.
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25.
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Secure the engine's main wiring harness with cable ties.
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26.
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Fit the air hose between the air collector casing and the turbocharger intake pipe.
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27.
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Fill up with coolant. For the correct mixture, see
Cooling system
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Close the filler cap.
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28.
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Fill up and bleed the system as follows:
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Note
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A/C and ACC must be OFF.
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Fill the system to MAX level, fit the pressure cap, start the engine and warm it up, preferably at varying engine speeds, 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.
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Raise the car to check for oil or coolant leakage.
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30.
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Lower the car and top up the coolant and/or oil as necessary.
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