Coolant pump, removing and fitting

Remove the ground cable.

Place a receptacle underneath

Open the drain screw (arrow)

Unscrew the coolant equalising container cap

Unscrew the lid on the oil filler connection

2x Unscrew

Screw on the lid on the oil filler connection

Pull off the cable set connector (2) - Heating conductor-mass air flow sensor

Undo the cable set (arrows)

Detach the engine ventilation hose (3)

Detach the intake hose (4)

5x Undo bolt

5x Undo bolt

Tension the multi-belt tensioning device in the direction of the arrow - Use KM-913-A (2) or a 15 mm flex-head spanner

Insert KM-6130 (1) or a 4 mm drift

Mark the direction of rotation

Tighten the multi-belt tension device. Remove KM-6130 (2)

Undo the multi-belt tension device

Undo the bolt (1)

Prise loose the front screw plug from the oil pan

Use KM-911 ( 83 96 327 Holder tool, fixing of flywheel )

Undo the bolt

Remove KM-911

3x Unscrew (1)

Detach from the rear tooth belt cover

Unscrew the nut - from the fuel line holder

Unscrew the stud

Pull off the camshaft sensor cable set connector

Undo the camshaft sensor cable set connector

Undo the bolt (arrow)

Detach from the rear tooth belt cover

Screw tight the bolt for the crankshaft multi-belt pulley

Set the crankshaft to the mark - Turn the crankshaft at a steady rate.

Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond (III)

Fix the camshaft sprockets.

Instruction: the markings must be in front of each other and agree with the top of the cylinder head (I) - Use KM-852 (83 96 319 Holder tool, fixing of camshaft sprocket Z18XE) (ll)

Undo the tooth belt tension roller (IV) - Undo the bolt - Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer (1) on the tooth belt tension roller is just short of the left-hand end position.

Undo the bolt (2)

Engine block

Important: check that the oil pump casting (1) engages in the groove in the coolant pump

Change the sealing ring

Moisten the sealing surface with silicone grease

3x Tighten bolt - Tightening torque 8 Nm

Important: the locking arm (1) for the tooth belt tensioning pulley must engage in the oil pump's guide jaw (2)

Tighten the bolt

Instruction: tighten the bolt after first adjusting the tooth belt tension

Screw tight the bolt for the crankshaft multi-belt pulley

Set the crankshaft to the mark - Turn the crankshaft at a steady rate.

Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond

Instruction: the pulling side must be taut (I)

Tension the tooth belt tensioning pulley - Turn the setting eccenter in the direction of the arrow (anticlockwise) until the pointer on the tooth belt tension roller is just short of the right-hand end position

Fasten the bolt for the tooth belt tensioning pulley (1)

Turn the crankshaft (720°) - on the bolt for the crankshaft multi-belt pulley

Instruction: in the direction of rotation of the engine

Put the crankshaft on the mark

Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond (III)

Put in KM-852 (83 96 319 Holder tool, fixing of camshaft sprocket Z18XE) (II)

Instruction: The markings must be in front of each other and agree with the top edge of the cylinder head (I)

Undo the tooth belt tensioning pulley - Undo the bolt

Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer (1) on the tooth belt tensioning pulley corresponds with the groove (2) - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark

Tighten the bolt for the tooth belt tensioning pulley - Tightening torque 20 Nm

Turn the crankshaft (720°)

Instruction: The pointer on the tooth belt tensioning pulley and the groove must agree - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark

Fasten the rear tooth belt cover

Tighten the bolt - Tightening torque 4 Nm

Fasten the camshaft sensor cable set connector

Fasten the camshaft sensor cable set connector - to the holder

Tighten the stud - Tightening torque 15 Nm

Tighten the nut - Tightening torque 15 Nm - From the fuel line holder

Fasten the rear tooth belt cover

3x Tighten bolt - Tightening torque 4 Nm

Tighten the bolt - Tightening torque 35 Nm

Tension the multi-belt tensioning device - Use KM-913-A or a 15 mm flex head spanner

Insert KM-6130 or a 4mm drift

Put in KM-911

Change the bolt

Tighten the bolt - Tightening torque 95 Nm + 30° + 15°

Remove KM-911

Fit the front screw plug

Instruction: Observe the rotation direction and fitting position

Undo the multi-belt tensioning device - Use KM-913-A

Remove KM-6130

4x Tighten bolt

Fit the intake hose

Fit the engine vent hose

Connect cable set connector

Fasten the cable set

Unscrew the lid on the oil filler connection

2x Tighten bolt - Tightening torque 8 Nm

Screw on the lid on the oil filler connection

Instruction: Fill and bleed the cooling system - See Cooling system, filling and bleeding .

Observe the prescribed amount of coolant