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Coolant pump

Coolant pump

To remove

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Carefully undo the cap on the expansion tank and release the pressure.

2. Unplug the connectors for the oxygen sensors and temperature sensor and carefully lower the cables.


3. Unplug the connector from the mass air flow sensor.


4. Detach the hose from the mass air flow sensor.

5. Remove the cover on the air cleaner casing.

6. Remove the filter element.


7. Detach the inlet air hose from the air cleaner casing.

8. Remove the air cleaner casing.

Important

Take care to ensure that the AC pressure sensor is not damaged when the air filter housing is removed.


9. Remove the inlet hose to the turbocharger, cover the turbocharger inlet.

10. Remove the upper bolt for the water pump in the timing cover and engine block.


11. Remove the heat shield over the turbocharger.


12. Remove the upper oxygen sensor.

13. Remove the nuts for the catalytic converter connection with the turbocharger.

14. Undo the bolt for the turbocharger oil delivery pipe.

15. Raise the car slightly.

16. Remove the front right wheel.

17. Lift the car a little more.

18. Remove the front spoiler shield .

19. Remove the right wing liner .

20. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.


21. Remove the lower bolt for the water pump in the timing cover and engine block.


22. Place a receptacle under the car, loosen the plug and drain the coolant pump.

23. Mark the direction of rotation, relieve the multigroove belt and remove it using 83 96 095 Belt circuit relieving tool B207 .


24. Remove the lower turbocharger pressure pipe.


25. Remove the front pipe .

26. Remove the heat shield over the steering gear.


27. Remove the heat shield over the catalytic converter.

28. Remove the temperature sensor.


29. Remove the lower oxygen sensor.

30. Remove the catalytic converter bracket from the engine block and the catalytic converter.

31. Remove the catalytic converter.

32. Remove the turbocharger coolant pipe from the thermostat housing and the turbocharger.


33. Remove the bolts on the thermostat housing.

34. Remove the coolant pump cover from the timing cover.


35. Position and fit 83 96 103 Coolant pump holder tool B207 to secure the balancer shaft pinion.

36. Remove the pinion bolts. Use a magnetic socket to remove the bolts from the holder.

37. Remove the bolts on the back of the coolant pump.


38. Move aside the thermostat housing with pipe and remove the coolant pump.

Important

It is normal for a very small amount of coolant to pass via the coolant pump shaft seal in order to lubricate it.


39. Remove the water pipe from the thermostat housing.


To fit


1. Clean and fit new O-rings on the coolant pipe, lubricate sparingly with Vaseline, non-acidic .


2. Clean the connections on the thermostat housing, fit a new seal and fit the water pipe.

3. Fit the stud to the coolant pump driver using 83 96 103 Holding tool for changing water pump, B207 from the tool kit.

4. Fit the coolant pump with new seal, sparingly lubricated with Vaseline, non-acidic by guiding in the stud through one of the holes in the balancer shaft sprocket.

5. Insert the coolant pump bolts, the two rear bolts and the lower bolt through the timing cover.


6. Lower the car.

7. Insert and tighten the upper bolt through the timing cover.


8. Raise the car.

9. Tighten the coolant pump bolts.

Tightening torque, short bolts 20 Nm (15 lbf ft).

Tightening torque, long bolts 25 Nm (18 lbf ft).

10. Fit the coolant pipe to the pump and fit the thermostat.

Tightening torque 10 Nm (7 lbf ft).


11. Fit the coolant pipe between the turbocharger and the thermostat housing with new seals.

Tightening torque 20 Nm (15 lbf ft) .

12. Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection.


13. Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.

14. Lower the car.

15. Lubricate the turbocharger studs with 30 20 971 Screw-thread paste .

16. Fit the catalytic converter with new nuts so that it is firmly against the turbocharger.

Tightening torque 10 Nm (7 lbf ft).


17. Tighten the turbocharger oil delivery pipe using new seals. Grip the pipe so that it does not rotate.

Tightening torque 15 Nm (11 lbf ft).

18. Raise the car.

19. Tighten the catalytic converter nuts and bolts a last time.

Tightening torque, bolts: 25 Nm (18.5 lbf ft)


20. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the lower oxygen sensor.

Tightening torque 40 Nm (30 lbf ft).

Important

Make sure that the oxygen sensor cables are not twined or damaged.


21. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the temperature sensor.

Tightening torque 45 Nm (33 lbf ft).

22. Lift up the oxygen sensor and temperature sensor cables.

Important

Make sure that no cables are pinched or chafed.


23. Fit the heat shield onto the catalytic converter.


24. Fit the heat shield over the steering gear.

25. Clean the joint on the catalytic converter and the pipe connection to the front silencer, mount the joint clamp and fit the front pipe with a new gasket, new nuts and rubber mountings. Lubricate the studs with 30 20 971 Screw-thread paste .


26. Move over the joint clamp so that the pipe ends are in the middle of the clamp.

27. Tighten the joint with the catalytic converter.

Tightening torque 25 Nm (18.5 lbf ft).

28. Tighten the joint clamp nuts.

Tightening torque 40 Nm (30 lbf ft).

29. Remove the stud and fit the bolts to the balancer shaft pinion using a 10mm magnetic socket.

Tightening torque, pinion 8 Nm (6 lbf ft), bearing 8 Nm (6 lbf ft).

Note

It may be necessary to remove the fixing tool for access before finally tightening with a torque wrench.



30. Fit the cover on the timing cover with a new gasket.

Tightening torque 8 Nm (6 lbf ft) .

31. Fit the multigroove belt in the direction of rotation noted earlier, making sure it is positioned correctly over the pulleys. Use 83 96 095 Belt circuit relieving tool B207 .


32. Fit the lower turbocharger delivery pipe.


33. Close the radiator drain.

34. Lower the car.

35. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the upper oxygen sensor.

Tightening torque 40 Nm (30 lbf ft).


36. Plug in and secure the oxygen sensor and temperature sensor connectors.


37. Fit the turbocharger heat shield.

Tightening torque 20 Nm (15 lbf ft).

38. Fit the air cleaner casing and connect the inlet hose.


39. Fit the filter and the air cleaner casing cover.


40. Fit the turbocharger inlet hose.

41. Plug in the mass air flow sensor connector.

42. Fill with coolant to approx. 20 mm above the mark on the expansion tank.

43. Check for coolant leaks.

44. Raise the car.

45. Fit the right wing liner and wheel .

46. Fit the front spoiler shield .

47. Lower the car.

48. Check the coolant level and top up as necessary.