Coolant pump, 4-cyl.
Coolant pump, 4-cyl. |
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To remove |
1. |
Open the cap on the expansion tank and release the pressure.
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2. |
Raise the car.
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3. |
Remove the lower front cover.
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4. |
Drain off the coolant.
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5. |
Lower the car to the floor.
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6. |
Unplug the mass air flow sensor connector.
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7. |
Remove the air hose and mass air flow sensor.
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8. |
Release the tension of the poly-V-belt using
83 95 254 Drawbar handle, hydraulic belt tensioner
.
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9. |
Remove the belt from the power steering pump and water pump.
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10. |
Disconnect the crankcase ventilation pipe from the turbo intake pipe using the quick coupling.
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11. |
Unplug the boost pressure control valve connector.
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12. |
Remove and move aside the engine's lifting lug and wastegate valve.
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13. |
Remove the bypass pipe with valve.
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14. |
Remove the exhaust manifold heat shield. The heat shield is attached with a nut and two clips underneath.
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15. |
Remove the turbo intake pipe.
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16. |
260 hp:
Remove the upper screw from the wastegate unit and slacken the lower screw.
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17. |
Remove the intake pipe.
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18. |
Remove the hose from the wastegate valve.
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19. |
Plug the turbo inlet using a plastic plug or the like.
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20. |
Undo the power steering pump.
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21. |
Move the power steering pump aside.
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22. |
Remove the hose clips and hoses on the coolant pump inlet.
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23. |
Detach the two longitudinal coolant pipes from the engine block.
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24. |
Detach the two longitudinal coolant pipes from the coolant pump.
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25. |
Slacken the bolt (by the turbo) securing the coolant pipe from the coolant pump.
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26. |
Remove the coolant pipe from the coolant pump.
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27. |
Undo the coolant pump retaining bolts.
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28. |
Carefully work the pump free from the bracket and from the pump's connecting sleeve on the engine block.
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29. |
Remove the connecting piece from the engine block and inspect its seals, Change the seals as necessary.
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To fit |
Note | ||
Spray the connectors with 30 04 520 Anti-corrosion agent . |
1. |
Connect the connecting piece to the cylinder block. Grease the seals with
White high-pressure grease paste
.
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2. |
Fit the coolant pump.
Tightening torque: 22 Nm (16 lbf ft) |
3. |
Fit and tighten the coolant pipe to the coolant pump and by the turbo.
Tightening torques Banjo screw, turbo: 25 Nm (18 lbf ft) Banjo screw, coolant pump: 20 Nm (15 lbf ft) |
4. |
Fit the two longitudinal coolant pipes to the coolant pump.
Tightening torque: 10 Nm (7 lbf ft) |
5. |
Fit the two longitudinal coolant pipes to the engine block.
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6. |
Fit the hose clips and hoses to the coolant pump inlet.
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7. |
Fit the power steering pump.
Tightening torque: 24 Nm (18 lbf ft) |
8. |
Remove the plug from the turbo intake and position the intake manifold. Fit a new O-ring if necessary and connect the hose to the wastegate valve.
Tightening torque, V clamp 3 Nm (2 lbf ft) |
9. |
260 hp:
Fit the wastegate unit.
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10. |
Fit the turbo's intake pipe. Align the pipe in with the help of the lifting eye.
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11. |
Fit the exhaust manifold heat shield.
Tightening torque, nut, heat shield: 20 Nm (15 lbf ft) (up to and including engine no. 7011078) 21 Nm (16 lbf ft) (from and including engine no. 7011079) |
13. |
Fit the engine lifting eye and wastegate valve.
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14. |
Plug in the boost pressure control valve connector.
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15. |
Fit the crankcase breather pipe to the turbo intake pipe.
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16. |
Fit the poly-V-belt and adjust the belt tensioner. Use a
83 95 254 Drawbar handle, hydraulic belt tensioner
.
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17. |
Fit the air hose and mass air flow sensor.
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18. |
Plug in the mass air flow sensor connector.
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19. |
Switch off the A/C or ACC. Fill with coolant to the MAX level. Refer to
Coolant
for mixtures. Do not forget to close the drain plug on the radiator first. Close the expansion tank lid.
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20. |
Start the engine and warm it up without load, preferably at varying speeds until the radiator fan cuts in.
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21. |
Turn off the engine and top up to the MAX level.
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22. |
Inspect the system for possible leaks.
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23. |
Raise the car.
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24. |
Fit the lower front cover.
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25. |
Lower the car to the floor.
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