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Coolant Pump, Remove and Install
 Remove
| 2. |
Remove right engine splash guard (2)
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Remove 2x body-bound rivets (3)
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| 3. |
Drain coolant
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Place collecting pan underneath.
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Attach suitable hose to drain connection (2)
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Open coolant drain screw (1)
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Close coolant drain screw
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| 4. |
Insert KM-6173 (3)
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Slacken 4x bolts (arrows) and hand-tighten
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Align KM-6173 at front axle body
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Wind up the support bearing (1)
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Journal (2) must sit in mount at cylinder block
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| 5. |
Attach KM-6001-A (1)
Note: Attaching KM-6001-A guarantees perfect alignment of the
drive unit with the front axle body
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Slacken 3x bolts (arrows) in adjusting rails
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Insert KM-6001-A
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The journals (2) and (5) must sit in the guide holes of the
front axle body
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Tighten 3x bolts in adjusting rails
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Adjust support bearings, front (4) and rear (3)
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Raise support bearings up to the stop on the guide journals
Note: The guide
journals must be seated free from play in the support bearings
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| 8. |
Remove air cleaner housing
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Disconnect mass air flow sensor wiring harness plug (2)
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Unclip tank vent line (3)
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Detach engine vent hose (4) from air intake hose
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Detach air intake hose (5) from throttle valve body
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Detach air cleaner housing
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Unclip rubber mounting at the bottom
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Remove air intake pipe (6)
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| 9. |
Remove engine damping block, right hand side
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Unscrew 6x bolts (1) and (2)
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Remove engine damping block with bracket
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| 10. |
Remove ribbed V-belt
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Mark direction of rotation
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Apply tension to ribbed V-belt tensioner (arrow) clockwise with
KM-6131
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Relieve tension on ribbed V-belt tensioner
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| 11. |
Detach engine damping block support (5) from timing case
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| 12. |
Disconnect wiring harness plug for coolant temperature sensor
(2)
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| 13. |
Detach coolant hoses (1), (4) and (7) from coolant pump
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| 14. |
Detach belt pulley (3) from coolant pump
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| 15. |
Remove coolant pump (2) from timing case
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Unscrew 9x bolts (1)
Note: Note different
bolt lengths
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Be careful of the guide sleeves when taking out the coolant
pump
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| 16. |
Clean sealing surfaces.
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Install
| 17. |
Install coolant pump
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Ensure guide sleeves are correctly seated (arrows)
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Tighten 9x bolt 8 Nm
Note: (1) = short
bolts
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| 18. |
Attach coolant hose to coolant pump
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| 19. |
Attach coolant hoses to coolant pump
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| 20. |
Connect coolant temperature sensor wiring harness plug
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| 21. |
Attach engine damping block support to timing case/cylinder
block
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| 22. |
Insert ribbed V-belt
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Position ribbed V-belt
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Ensure correct running direction and installation position
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Apply tension to ribbed V-belt tensioner with KM-6131
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Relieve tension on ribbed V-belt tensioner
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| 23. |
Fit engine damping block to body
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Tighten 3x bolt (2) 35 Nm
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| 24. |
Attach engine damping block bracket to engine damping block
support
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Tighten 3x bolt (1) 55 Nm
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| 25. |
Install air cleaner housing
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Attach air cleaner housing to wheelhouse
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Attach air intake hose to throttle valve module
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Attach engine vent hose to timing case
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Connect wiring harness plug, air mass flow meter
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| 27. |
Remove KM-6001-A and KM-6173
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| 28. |
Attach right engine splash guard
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Install 2x body-bound rivets
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| 30. |
Fill and bleed cooling system 
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