Water Pump: Service and Repair

Notes: Always replace seals and gaskets.

Removing





^ Remove engine cover.





^ Disconnect air duct at bottom of right - hand longitudinal member (air duct leads to charge air cooler).
^ Drain coolant system.





^ Remove center and right - hand sections of noise insulation - arrows -.
^ Remove ribbed belt and tensioning element.
^ Disconnect vacuum hose from activated charcoal filter and from throttle valve connection.





^ Remove coolant expansion tank (left arrows) together with hoses.
^ Unbolt power steering reservoir (right arrow). Do not disconnect the hoses.
^ Remove toothed belt guards (upper and center).





^ Set crankshaft to markings for TDC of No. 1 cylinder - arrows - by turning central bolt on crankshaft sprocket in direction of rotation.





^ Screw M5x55 stud - 1 - into toothed belt tensioning element. Screw hexagonal nut -2 - onto stud - 1 - using large washer - 3 -.
^ Tension pressure piston of tensioning element only until it can be secured with a locking pin (e.g. from lifting appliance 2024 A) - arrow-.

Notes: If it is not possible to insert the locking pin, carefully tension the pressure piston of the tensioning element just enough to allow the toothed belt to be removed.

^ Remove toothed belt from camshaft sprocket.

Notes:
^ The vibration damper and bottom toothed belt guard do not have to be removed.
^ The toothed belt should be left in position on the crankshaft sprocket.
^ Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.

Vehicles with air conditioning:
^ Remove lower air duct.





All models
^ Unscrew coolant pump securing bolts - 1 - and remove coolant pump - 2 -.

Installing
Installation is carried out in the reverse order:
^ Clean and smooth down sealing surface for O - ring as required.
^ Moisten new O - ring with coolant G 012 AS D.
^ Install coolant pump. Installation position: plug in housing faces downward.
^ Install toothed belt (adjust valve timing).

Notes: Follow all the instructions on removing and installing the toothed belt.

^ Install ribbed belt and tensioning element.
^ Fill up with coolant.





Tightening torque