J609100 Coolant Pump, Remove and Install (Z 18 XE,
with Air Conditioning, LHD)
Note: KM-6394 must be used as of model year 04 instead of
KM-6169-1 .
Remove
2. |
Disconnect battery
Note: In vehicles from
model year 04 onwards with ESP - the steering angle sensor loses
its basic adjustment each time the battery is disconnected and must
be recalibrated.
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3. |
Remove engine cover.
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Unscrew oil filler pipe cap
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Screw on oil filler pipe cap
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4. |
Remove air cleaner housing (1)
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Disconnect 2 wiring harness plugs
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Hot film mass air flow meter (4), tank vent valve (2)
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Detach engine vent hose (3)
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5. |
Remove upper part of toothed belt cover
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Unscrew 3 bolts (arrows)
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Unclip from rear toothed belt cover
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7. |
Remove right-hand air duct
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Unscrew 3 bolts (arrows)
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8. |
Remove ribbed V-belt cover
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10. |
Detach front right wheel
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12. |
Remove right front wheel.
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14. |
Remove ribbed V-belt
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Tension ribbed V-belt tensioner in direction of arrow with
KM-913-A (2)
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15. |
Remove ribbed V-belt tensioner
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Tension ribbed V-belt tensioner.
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Release ribbed V-belt tensioner
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16. |
Detach crankshaft ribbed V-belt pulley
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Prise front closure plug out of oil pan
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17. |
Release lower part of toothed belt cover
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Unclip from rear toothed belt cover
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19. |
Remove lower part of toothed belt cover
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Unclip from rear toothed belt cover
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20. |
Attach KM-6169 (1)
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Attach KM-6169 to left of front axle
body (arrows, illus. I)
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Guide pin must be seated in bore in front axle body
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Attach both right holders on the front axle body (arrows,
Illus. II).
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Guide pin must be seated in bore in front axle body (arrow,
Fig. III)
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21. |
Install support
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An KM-6169
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Adjust bracket (2) for support
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22. |
Adjust supports
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Transmission side
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Turn spindles until mounts (3) are positioned at guide journals
free of play
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Engine timing side
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Insert journal of the support in the bore of the cylinder block
without play (arrow)
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24. |
Remove right engine damping block
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Loosen engine bracket adapter
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Loosen engine damping block
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25. |
Remove upper part of toothed belt cover
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Unscrew 3 bolts (arrows)
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Unclip from rear toothed belt cover
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26. |
Disconnect camshaft sensor wiring harness plug
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27. |
Remove lower part of toothed belt cover
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Unclip from rear toothed belt cover
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28. |
Set 1st cylinder to TDC of combustion stroke
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Install crankshaft V-belt pulley bolt
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Set crankshaft to mark.
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Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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Fix camshaft sprockets in position.
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Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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29. |
Remove toothed belt
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Release toothed belt tension roller (IV)
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Turn adjusting eccentric in direction of arrow (clockwise)
until pointer (1) of the toothed belt tension roller is located
just before left stop.
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31. |
Remove toothed belt drive pulley
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Unscrew crankshaft ribbed V-belt pulley bolt
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32. |
Release rear toothed belt cover
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Unscrew 2 bolts (arrows)
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33. |
Remove intake side toothed belt guide roller
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34. |
Remove exhaust side toothed belt guide roller
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35. |
Remove right engine bracket (3)
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36. |
Remove toothed belt tension roller
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38. |
Drain coolant
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Place collecting basin underneath.
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Open drain bolt (arrow)
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40. |
Remove coolant pump
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Unscrew 3 bolts (arrows)
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Install
41. |
Clean cylinder block sealing surfaces
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42. |
Inspect components
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Ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulleys,
toothed belt drive
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43. |
Install coolant pump
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Coat sealing surface with silicone grease
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Carefully prise off rear toothed belt cover
Note: Ensure that the
lug of the oil pump (1) engages in the groove of the coolant
pump
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45. |
Fasten rear toothed belt cover
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46. |
Install toothed belt drive gear
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Install crankshaft V-belt pulley bolt
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48. |
Install toothed belt tension roller
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Detent lever (1) of toothed belt tension roller must engage in
guide web (2) of oil pump.
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Bolt in bolt
Note: Adjust toothed
belt tension before tightening bolt.
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49. |
Install right engine bracket
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Insert bolts with locking compound (red)
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Tighten 3x bolts 65 Nm + 45° -
60°
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50. |
Install intake side toothed belt guide roller
Note: The toothed belt
guide roller with the greater diameter is installed at the intake
side.
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51. |
Install exhaust side toothed belt guide roller
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52. |
Fix camshaft sprockets in position.
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Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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Use KM-852 (II)
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Turn the camshafts at hexagonal section
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53. |
Lock crankshaft
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Set crankshaft to mark.
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Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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54. |
Inspect components
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Ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulleys,
toothed belt drive
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55. |
Install toothed belt
Note: Pay attention to
direction of travel and timing marks.
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Position toothed belt
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Tensioned side must be taut.
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56. |
Tension toothed belt
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Tension toothed belt tension roller
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Turn adjusting eccentric in direction of arrow (anticlockwise)
until pointer of the toothed belt tension roller is located just
before left stop
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Fasten toothed belt tension roller bolt (1)
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58. |
Timing, Check
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Turn crankshaft in direction of engine rotation at the
crankshaft ribbed V-belt pulley bolt (720°)
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Set crankshaft to mark.
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Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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Use KM-852 (II)
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Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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60. |
Adjust toothed belt tension
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Release toothed belt tension roller
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Turn adjustment eccentric in the direction of the arrow
(clockwise) until pointer (1) of toothed belt tension roller is
aligned with the notch mark NEW (2).
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Tighten toothed belt tension roller bolt 20 Nm
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61. |
Check toothed belt tension
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Pointer on the toothed belt tension roller and notch mark NEW
must align
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62. |
Install lower part of toothed belt cover
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Clip to rear of toothed belt cover
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63. |
Install upper part of toothed belt cover
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Clip to rear toothed belt cover
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64. |
Connect camshaft sensor wiring harness plug
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Connect wiring harness plug
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65. |
Install right engine damping block
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Fasten engine bracket adapter
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Tighten 2x bolts 60 Nm + 30° -
45°
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Fasten engine damping block
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69. |
Install ribbed V-belt tensioner
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Tension ribbed V-belt tensioner with KM-913-A
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70. |
Attach crankshaft ribbed V-belt pulley
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Tighten bolt 95 Nm + 30° +
15°
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Insert front closure plug
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71. |
Install ribbed V-belt
Note: Observe running
direction and installation position
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Slacken ribbed V-belt tensioner with KM-913-A
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72. |
Install ribbed V-belt cover
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73. |
Install right-hand air duct
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75. |
Attach front right wheel
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77. |
Fasten right front wheel.
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78. |
Install air cleaner housing
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Attach engine vent hose
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Clip in tank vent valve
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Connect 2 wiring harness plugs
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79. |
Install engine cover.
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Unscrew oil filler pipe cap
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Screw on oil filler pipe cap
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81. |
Calibrate steering angle sensor
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Rotate the steering wheel one time from its right-hand to its
left-hand stop
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82. |
Program volatile memories
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