Water Pump: Service and Repair

REMOVAL

Fig. 2 Balance shaft drive & camshaft drive exploded view.:

1. Drain coolant from cold engine by setting heater control lever to warm position and unscrew drain plug.
2. Disconnect negative battery cable.
3. Remove lower radiator hose.
4. Remove accessory drive belts.
5. Remove upper and lower front timing belt covers.
6. Rotate engine to TDC cylinder #1.

Crankshaft Timing Marks:

7. Ensure alignment of timing marks on flywheel and clutch housing.

Camshaft Timing Marks:

8. Ensure alignment of timing marks on camshaft and rear timing cover.

Lower Balance Shaft Timing Mark:

Upper Balance Shaft Timing Mark:

9. Ensure alignment of balance shaft marks.

Distributor Console:

10. Remove distributor cap, distributor rotor, distributor protective cover, and distributor cap console.
11. Loosen balance shaft tensioning rollers and remove balance shaft drive belt.
12. Remove balance shaft drive gears.
13. Loosen timing belt tensioning roller and remove timing belt.
14. Remove crankshaft pulleys and drive gears.
15. Remove rear timing cover.

Water Pump Assembly:

16. Remove water pump retaining bolts and remove water pump.
17. Exchange parts on water pump as necessary.

NOTE:
- Check the condition of the balance shaft and the camshaft seals. Replace as necessary.
- Porsche recommends updating the water pump to a newer style pump, see TSB # 18713 for detailed instructions.

INSTALLATION
- Scrape gasket as required.
- Reinstall water pump.
- Reinstall rear timing cover, torque bolts to 8 Nm (6 ft lbs).
- Place timing belt around the crankshaft sprocket, tensioning roller, water pump pulley, and camshaft pulley.

Belt Tension Tool:

Positioning Tension Tool On Cam Belt:

- Install special tool 9201, Tools and Equipment Pull out lockpin and push out test pin. Align drag needle with gauge needle.
- Apply pressure to gauge bar at test point until lock pin engages. Displayed value should be 4.0 +/- 0.3 for new belts and 2.7 +/- 0.3 for used belts.

NOTE Do not twist or apply pressure to belt or gauge while taking readings. This will affect the gauge reading.

- Turn tensioning roller counterclockwise to tighten belt and clockwise to loosen. While holding tensioning roller, tighten lock nut.
- Turn engine one complete revolution and recheck belt tension.
- Ensure alignment of balance shaft marks. Install balance shaft belt.
- Using special tool 9201, tighten balance shaft belt to 2.7 +/- 0.3, Adjustments
- Rotate engine one full revolution and recheck belt tension.
- Finish installation by reversing removal procedures.
- Replace drain plug. Remove bleeder plugs. Slowly add coolant until fluid level remains at the "max" mark in the expansion tank.
- Start and run engine at fast idle until radiator fan switches on and off adding coolant as necessary.
- When fluid leaving bleeder is free from air bubbles replace bleeder plug.
- Ensure proper coolant level in expansion tank.