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PRE-RELEASE

Coolant pump, V6

Coolant pump, V6

To remove

Warning

Removal of the fuel rail involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.

• Absolutely No Smoking!

• Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.



1. Undo the cap on the expansion tank.

2. Raise the car and remove the lower engine cover.


3. Detension and remove the multigroove V-belt. Remove the belt tensioner.


4. Place a suitable receptacle under the car and drain the radiator.

5. Undo the front bolt on the front torque arm.


6. Remove the lower bolt securing the dipstick pipe.

7. Lower the car and remove the intake pipe with mass air flow sensor from the turbocharger.


8. Remove the upper engine cover.

9. Disconnect the upper radiator hose.

10. Unplug the fan connectors.


11. Remove the upper bolt securing the lifting eye and remove the dipstick pipe from the lifting eye.

12. Move aside the lifting eye and remove the fan cowling.

13. Remove the nut for the rear engine mounting.


14. Undo the quick-release couplings on the fuel lines. Use a rag to catch any fuel.


15. Take up the weight of the engine using a jack. Remove the right-hand engine mounting with the bracket and engine pad. Raise the engine slightly and remove the engine mounting bolts. Remove the lower engine bracket.

16. Remove the timing belt cover.


17. Zero the engine, aligning the crankshaft pulley, camshaft pulleys and fuel pump pulley with the markings on the engine.


18. If the markings on the belt are unclear, remark the belt to correspond with the marks on the pulleys.

19. Insert a 6 mm drill bit or similar into the hole in the tensioner pulley to relieve the pressure. Remove the tensioner pulley by undoing the bolt and simultaneously withdrawing the pulley.


20. Remove the timing belt and idler pulley. If the markings on the belt are unclear, remark the belt to correspond with the marks on the pulleys.

21. Remove the plug above the fuel pump pulley. Screw an M6 bolt into the pulley to lock it in position.


22. Remove the fuel pump pulley.


23. Remove the crankshaft pulley and idler pulley.

24. Unplug the connector for the timing sensor.

25. Remove the timing cover. Remove the seals and clean the sealing surfaces of the cover of gasket remains.


26. Remove the timing sensor's toothed wheel and the two idler gears of the pump transmission.


27. Remove the coolant pump.



To fit


1. Fit the coolant pump. Use a new gasket. Make sure the two long bolts are in the correct position.


2. Fit the timing sensor's toothed wheel and the two idler gears of the pump transmission. Make sure that the markings are aligned.


3. Fit the timing cover. Apply a bead of flange sealant, part no. 87 81 841, into the recess around the cover .


4. Fit the sealing ring in the fuel pump recess. Use 83 95 758 Fitting tool, fuel pump seal .


5. Fit the sealing ring for the crankshaft. Use 83 95 717 Fitting tool, crankshaft seal, front .


6. Plug in the timing sensor connector.


7. Fit the crankshaft pulley and idler pulley.

8. If the belt tensioner has been released, compress it using a vice and fit the locking pin. Fit the belt tensioner. Fit the belt so that the markings are aligned with those on the pulleys.


9. Fit the idler pulleys and remove the locking pin.


10. Turn over the engine twice and check that the markings on the pulleys are aligned with those on the covers.


11. Fit the cam belt cover.


12. Fit the right-hand engine mounting with bracket and engine pad. Raise the engine slightly to insert the engine bracket bolts.

Tightening torque 47 Nm (35 lbf ft)


13. Fit the quick-release couplings on the fuel lines.

14. Lower the engine and remove the jack. Fit the nut to the right-hand engine mounting.

Tightening torque 47 Nm (35 lbf ft)

15. Fit the nut to the rear engine pad.

Tightening torque 47 Nm (35 lbf ft)


16. Move aside the lifting eye and fit the fan cowling.


17. Fit the upper bolt securing the lifting eye and secure the dipstick pipe to the lifting eye.

18. Plug in the fan connectors.

19. Fit the upper radiator hose.


20. Fit the upper engine cover.

21. Fit the intake pipe with mass air flow sensor. Plug in the mass air flow sensor connector.

Tightening torque, mass air flow sensor: 3.5 Nm (2.5 lbf ft)

22. Fit the multigroove V-belt.


23. Raise the car and tighten the bolt securing the dipstick pipe.


24. Fit the front bolt to the torque arm.

Tightening torque 90 Nm + 90° (66 lbf ft + 90°)

25. Fit the lower engine cover and lower the car.


26. Bleed the fuel system as described under Bleeding the fuel system.

27. Fill with coolant and bleed the cooling system as described under Bleeding the cooling system


PRE-RELEASE