Coolant pump
Coolant pump |
To remove |
|
1. |
Carefully undo the cap on the expansion tank to 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.
|
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 right wing liner
.
CV:
Remove
Chassis reinforcement, front subframe, CV
|
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 and connect a hose to the coolant pump drain cock. Open the cock 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 lower oxygen sensor.
|
29. |
Remove the catalytic converter bracket from the engine block and the catalytic converter.
|
30. |
Remove the catalytic converter.
|
31. |
Remove the turbocharger coolant pipe from the thermostat housing and the turbocharger.
|
32. |
Remove the bolts on the thermostat housing.
|
33. |
Remove the coolant pump cover from the timing cover.
|
34. |
Position and fit
83 96 103 Coolant pump holder tool B207
to secure the balancer shaft pinion.
|
35. |
Remove the pinion bolts. Use a magnetic socket to remove the bolts from the holder.
|
36. |
Remove the bolts on the back of the coolant pump.
|
37. |
Move aside the thermostat housing with pipe and remove the coolant pump.
|
38. |
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).
|
21. |
Lift up the oxygen sensor cable.
|
22. |
Fit the heat shield onto the catalytic converter.
|
23. |
Fit the heat shield over the steering gear.
|
24. |
Clean the joint on the catalytic converter and the pipe connection to the front silencer. Mount the joint clamp.
|
25. |
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). |
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.
CV:
Fit
Chassis reinforcement, front subframe, CV
.
|
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 connector.
|
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.
|