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Replace coolant pump
 Remove
| 1. |
Remove air filter housing with mass air flow meter
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Detach mass air flow meter wiring harness plug (3)
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| • |
Detach air intake hose from air intake pipe
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| 2. |
Remove fastening bolts (1) and remove top front toothed belt
cover from rear toothed belt cover
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| 3. |
Mark direction of travel of ribbed V-belt.
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| 4. |
Tension ribbed V-belt tensioner in direction of arrow
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| 6. |
Remove lower engine splash guard.
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| 7. |
Tension ribbed V-belt tensioner (clockwise)
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Lock using suitable drift
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| 8. |
Undo fastening screws (1) and remove ribbed V-belt
tensioner
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Remove from compressor support
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| 9. |
Remove torsional vibration damper
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Counterhold at toothed belt drive gear fastening bolt
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| 10. |
Remove fastening bolts (1)
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Detach lower section of toothed belt cover from rear toothed
belt cover
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| 11. |
Drain coolant
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Open drain bolt on radiator (1)
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| 12. |
Turn the crankshaft in the direction of engine rotation to
"Cylinder no.1 TDC" using the fastening bolt for the toothed belt
drive gear
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| 13. |
At the same time, the notches on the camshaft pulleys must
align with the marks (1) on the cylinder head cover
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| 14. |
Lock camshaft with KM-853 (2)
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| 15. |
Release toothed belt tension roller and remove toothed belt
from camshaft pulleys
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| 16. |
Detach toothed belt tension roller (1)
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| 17. |
Remove fastening bolts (arrows) and remove coolant pump
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| 18. |
Clean sealing surfaces and remove gasket remnants.
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Install
| 19. |
Before installing coolant pump, coat sealing surface with
silicone grease (white)
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| 20. |
Attach coolant pump to cylinder block with new seal ring 25 Nm
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| 21. |
Lug (2) of coolant pump must align with relevant counterpart
(1) on cylinder block
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| 22. |
Attach toothed belt tension roller to oil pump
Note: Ensure that
detent lever (1) engages in oil pump guide web - tightening to
torque does not take place until toothed belt tension has been
adjusted.
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| 23. |
Close coolant drain screw
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| 24. |
Position toothed belt
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| 26. |
Attach lower section of toothed belt cover to rear toothed belt
cover 6 Nm
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| 27. |
Attach torsional vibration damper to toothed belt drive gear
20 Nm
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Counterhold at toothed belt drive gear fastening bolt
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| 28. |
Attach ribbed V-belt tensioner to compressor support 25 Nm
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| 29. |
Tension ribbed V-belt tensioner (clockwise) and remove fixing
rod.
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| 30. |
Install lower engine splash guard.
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| 31. |
Position ribbed V-belt
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Ensure running direction and installation position of ribbed
V-belt is correct
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| 32. |
Tension ribbed V-belt using ribbed V-belt tensioner
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| 33. |
Attach top front toothed belt cover to rear toothed belt cover
6Nm
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| 34. |
Install air cleaner housing with mass air flow meter
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Insert air cleaner housing
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Attach air intake hose to air intake pipe
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| • |
Connect mass air flow meter wiring harness plug
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| 35. |
Always use antifreeze 19 40 650 / 9194431 (red) and ensure that
the concentration is 50% water and 50% antifreeze. The antifreeze
does not just protect the entire cooling system from freezing, but
also protects all coolant-flushed parts from rust-corrosion/calcium
deposits. It is therefore important to add antifreeze, even in
tropical countries.
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| 36. |
The water quality also plays an important role in addition to
the mix ratio. Water of drinkable quality usually meets these
requirements. The quality of purified sea water is inadequate!
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| 37. |
Damage may also be caused to the engine if unauthorised
anti-freeze agent is used!
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| 38. |
If radiator, cylinder head or cylinder head gasket have been
replaced the old coolant must not be re-used.
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Important: Vehicles with air
conditioning: switch air conditioning off and set to ECO mode with
ECC
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| 39. |
Open cooling system
Warning: Cooling system is under
pressure
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| • |
Unscrew coolant expansion tank cover
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| 40. |
Fill with coolant up to lower venting line (1) at coolant
expansion tank
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| 41. |
Seal off cooling system
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Screw in coolant expansion tank cover
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| 42. |
Start engine and allow to warm up
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Allow engine to warm up at idling speed of up to 2500 rpm until
first radiator fan setting switches on
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| 43. |
Vent cooling system
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Allow engine to run for approximately 2 minutes at 2000 to 2500
rpm
Note: The air in the
cooling system is removed via the venting lines
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| 44. |
Switch engine off and allow to cool
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| 45. |
Check coolant level and also top up coolant to "COLD" mark
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