Removing the additional coolant pump
Note. Cover the engine. For this work, the worker must lie on the engine. The additional coolant pump is difficult to reach.
1. Cover the intake-air distributor with covers.
Scheme 52
2. Open both plastic clips of the rear valve cover wiring harness and lay the wiring harness aside -1-. (Scheme 52)
3. Loosen both fastening nuts of the engine wire harness on the top chain case lid and push the engine wire harness to the side.
Scheme 53
4. Disconnect cable plug of the additional coolant pump. Pull out additional coolant pump laterally from the rubber mountings. Pull off spring band clamps -1 and 2- of the coolant hoses. (Scheme 53)
Scheme 54
Note. If one or more rubber sleeves slide out of the sheetmetal holder when inserting the additional coolant pump, grab the rubber sleeves with a pointed-nose pliers and pull them up through the holes in the sheetmetal holder.
1. Mount the coolant hoses and spring band clamps on the additional coolant pump -1 and 2-. Connect the additional coolant pump laterally into the rubber mounting. Push on cable plug. see scheme 97
2. Mount wiring harnesses. Tighten fastening nuts --> Tightening torque: 6 ftlb. . Clip in the component.
1. Fill coolant and bleed system > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"
2. Mount right engine compartment covers and center plenum panel Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .
Scheme 55
3. Mount design cover.
1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)
2. Remove the radiator frame. > 193817 Draining and filling coolant (includes bleeding)
Scheme 56
Scheme 57
1 - Coolant pump
2 - Seal for coolant pump (replace seal)
3 - 2 dowel sleeves (do not remove)
4 - 8 M6 x 25 fastening screws (tightening torque 10 Nm (7.5 ftlb.))
5 - Support for cable duct (fit with the two upper fastening screws)
Scheme 58
1. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.
Scheme 59
2. Remove the throttle adjuster.
Scheme 60
Note. To ease removal, spray the pulley from the rear side with an anti-corrosion agent.
3. Unscrew the three fastening screws on the coolant pump pulley. Wrench size is T 40.
Scheme 61
4. Remove the drive belt from the coolant pump pulley. Mark the direction of running of the drive belt with chalk.
Scheme 62
5. Use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise and, at the same time, remove the drive belt from the tensioning roller. Relieve the belt tensioner carefully. Remove the drive belt from the coolant pump.
| CAUTION | Risk of damaging pulley! |
> The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.
> The pulley is sensitive to impacts.
> Do not pry off the pulley with a screwdriver.
6. Remove the 3 loosened fastening screws on the pulley and remove the pulley.
Scheme 63
7. Remove the eight fastening screws on the coolant pump and remove the pump. If the pump is stuck, loosen it by gently tapping with a plastic hammer.
