PRE-RELEASE
Coolant pump, removing and fitting
| Coolant pump, removing and fitting |
| To remove |
| 1. |
Open the bonnet
|
|
| 2. |
Disconnect the battery.
Remove the ground cable. |
|
| 3. |
Drain the coolant
Place a receptacle underneath Open the drain screw (arrow) Unscrew the coolant equalising container cap 
|
|
| 4. |
Remove the engine cover.
Unscrew the lid on the oil filler connection 2x Unscrew Screw on the lid on the oil filler connection |
|
| 5. |
Remove the air cleaner casing (1)
Pull off the cable set connector (2) - Heating conductor-mass air flow sensor Undo the cable set (arrows) Detach the engine ventilation hose (3) Detach the intake hose (4) 
|
|
| 6. |
Undo the front right wheel
5x Undo bolt |
|
| 7. |
Raise the car
|
|
| 8. |
Remove the right front wheel.
5x Undo bolt |
|
| 9. |
Remove the wing liner
|
|
| 10. |
Remove the multi-belt
Tension the multi-belt tensioning device in the direction of the arrow - Use KM-913-A (2) or a 15 mm flex-head spanner Insert KM-6130 (1) or a 4 mm drift Mark the direction of rotation 
|
|
| 11. |
Remove the multi-belt tension device
Tighten the multi-belt tension device. Remove KM-6130 (2) Undo the multi-belt tension device Undo the bolt (1) 
|
|
| 12. |
Remove the crankshaft multi-belt pulley
Prise loose the front screw plug from the oil pan Use KM-911 ( 83 96 327 Holder tool, fixing of flywheel ) Undo the bolt Remove KM-911 
|
|
| 13. |
Lower the car
|
|
| 14. |
Remove the top part of the tooth belt cover
3x Unscrew (1) Detach from the rear tooth belt cover 
|
|
| 15. |
Undo the camshaft sensor cable set connector
Unscrew the nut - from the fuel line holder Unscrew the stud Pull off the camshaft sensor cable set connector Undo the camshaft sensor cable set connector |
|
| 16. |
Remove the bottom of the tooth belt cover
Undo the bolt (arrow) Detach from the rear tooth belt cover 
|
|
| 17. |
Set ignition TDC cylinder 1
Screw tight the bolt for the crankshaft multi-belt pulley Set the crankshaft to the mark - Turn the crankshaft at a steady rate. Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond (III) Fix the camshaft sprockets. Instruction: the markings must be in front of each other and agree with the top of the cylinder head (I) - Use KM-852 (83 96 319 Holder tool, fixing of camshaft sprocket Z18XE) (ll) 
|
|
| 18. |
Remove the tooth belt
Undo the tooth belt tension roller (IV) - Undo the bolt - Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer (1) on the tooth belt tension roller is just short of the left-hand end position. |
|
| 19. |
Remove the tooth belt tensioning pulley (1)
Undo the bolt (2) 
|
|
| 20. |
Remove the coolant pump • 3x Undo the bolt (arrows)
|
|
| To fit |
| 1. |
Clean the sealing service
Engine block |
|
| 2. |
Fit the coolant pump
Important: check that the oil pump casting (1) engages in the groove in the coolant pump Change the sealing ring Moisten the sealing surface with silicone grease 3x Tighten bolt - Tightening torque 8 Nm 
|
|
| 3. |
Fit the tooth belt tensioning pulley
Important: the locking arm (1) for the tooth belt tensioning pulley must engage in the oil pump's guide jaw (2) Tighten the bolt Instruction: tighten the bolt after first adjusting the tooth belt tension 
|
|
| 4. |
Check the TDC cylinder 1
Screw tight the bolt for the crankshaft multi-belt pulley Set the crankshaft to the mark - Turn the crankshaft at a steady rate. Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond |
|
| 5. |
Put on the tooth belt
Instruction: the pulling side must be taut (I) 
|
|
| 6. |
Tension the tooth belt
Tension the tooth belt tensioning pulley - Turn the setting eccenter in the direction of the arrow (anticlockwise) until the pointer on the tooth belt tension roller is just short of the right-hand end position Fasten the bolt for the tooth belt tensioning pulley (1) 
|
|
| 7. |
Remove KM-852 (
83 96 319 Holder tool, fixing of camshaft sprocket Z18XE
)
|
|
| 8. |
Valve timing, check
Turn the crankshaft (720°) - on the bolt for the crankshaft multi-belt pulley Instruction: in the direction of rotation of the engine Put the crankshaft on the mark Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond (III) Put in KM-852 (83 96 319 Holder tool, fixing of camshaft sprocket Z18XE) (II) Instruction: The markings must be in front of each other and agree with the top edge of the cylinder head (I) 
|
|
| 9. |
Remove KM-852
|
|
| 10. |
Tooth belt tension, setting
Undo the tooth belt tensioning pulley - Undo the bolt Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer (1) on the tooth belt tensioning pulley corresponds with the groove (2) - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark Tighten the bolt for the tooth belt tensioning pulley - Tightening torque 20 Nm 
|
|
| 11. |
Tooth belt tension, check
Turn the crankshaft (720°) Instruction: The pointer on the tooth belt tensioning pulley and the groove must agree - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark |
|
| 12. |
Fit the bottom of the tooth belt cover
Fasten the rear tooth belt cover Tighten the bolt - Tightening torque 4 Nm |
|
| 13. |
Connect the camshaft sensor cable set connector
Fasten the camshaft sensor cable set connector Fasten the camshaft sensor cable set connector - to the holder Tighten the stud - Tightening torque 15 Nm Tighten the nut - Tightening torque 15 Nm - From the fuel line holder |
|
| 14. |
Fit the top of the tooth belt cover
Fasten the rear tooth belt cover 3x Tighten bolt - Tightening torque 4 Nm |
|
| 15. |
Raise the car
|
|
| 16. |
Fit the multi-belt tensioning device
Tighten the bolt - Tightening torque 35 Nm Tension the multi-belt tensioning device - Use KM-913-A or a 15 mm flex head spanner Insert KM-6130 or a 4mm drift 
|
|
| 17. |
Fit the crankshaft multi-belt pulley
Put in KM-911 Change the bolt Tighten the bolt - Tightening torque 95 Nm + 30° + 15° Remove KM-911 Fit the front screw plug |
|
| 18. |
Fit the multi-belt
Instruction: Observe the rotation direction and fitting position Undo the multi-belt tensioning device - Use KM-913-A Remove KM-6130 |
|
| 19. |
Fit the multi-belt guard
4x Tighten bolt |
|
| 20. |
Lower the car
|
|
| 21. |
Fit the front right wheel
|
|
| 22. |
Lower the car
|
|
| 23. |
Fit the air filter housing
Fit the intake hose Fit the engine vent hose Connect cable set connector Fasten the cable set |
|
| 24. |
Replace the engine cover.
Unscrew the lid on the oil filler connection 2x Tighten bolt - Tightening torque 8 Nm Screw on the lid on the oil filler connection |
|
| 25. |
Connect the battery.
|
|
| 26. |
Fill with coolant
Instruction: Fill and bleed the cooling system - See Cooling system, filling and bleeding . Observe the prescribed amount of coolant |
|
| 27. |
Program any erased memories
|
|
| 28. |
Close the bonnet
|
|
