Installing 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 pryoff the pulley with a screwdriver.
Scheme 60
1. Clean sealing surfaces. Mount new sheetmetal seal on the coolant pump. Slide the new sheetmetal seal over the dowel pins.
Scheme 61
2. Tighten the 8 fastening screws. --> Tightening torque: 7.5 ftlb. Mount the sheetmetal holder for the cable duct using the two upper fastening screws.
3. Fit the pulley on the coolant pump. Screw in the three fastening screws by hand.
4. Mount drive belt -as shown in the following-. To do this, turn the belt tensioner clockwise and thread the drive belt around all the pulleys. Then carefully relieve the tensioning roller. Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIP, Cayenne S MAN). Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S). (Scheme 62)
Scheme 62
5. Check whether the drive belt is correctly installed.
6. Tighten the three fastening screws of the coolant pump pulley. --> Tightening torque: 17 ftlb.
7. Tighten the throttle adjuster with new seal. --> Tightening torque: 17 ftlb.
8. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.
1. Install the radiator frame. > 192019 Removing and installing cooling fan housing (radiator frame) - chapter on "Installing"
2. Fill and bleed the cooling system according to instructions. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"
1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)
Scheme 63
1- - Coolant pipe. (Scheme 63)
2- - Wiring for reservoir. (Scheme 63)
3- - Thermostat housing. (Scheme 63)
4- - Connection wires on cylinder block. (Scheme 63)
5- - Connections on oil/water heat exchanger. (Scheme 63)
6- - Coolant pipe. (Scheme 63)
7- - Coolant hose; flange must engage with an audible click. (Scheme 63)
8- - --> Tightening torque: 2 ftlb.. (Scheme 63)
9- - O-ring; replacing. (Scheme 63)
10- - Fuel feed direction of coolant pump. (Scheme 63)
11- - --> Tightening torque: 15 ftlb.. (Scheme 63)
12- - Pulley (Scheme 63)
13- - --> Tightening torque: 6 ftlb.. (Scheme 63)
14- - Coolant pump; check for smooth operation. (Scheme 63)
15- - Direction of flow - coming from radiator. (Scheme 63)
16- - Hose line - coming from radiator. (Scheme 63)
17- - --> Tightening torque: 6 ftlb.. (Scheme 63)
Scheme 64
1. Mark the rolling direction of the drive belt with chalk.
Scheme 65
2. Relieve and remove drive belt. To do this, screw an M8 screw into the belt tensioner.
Scheme 66
Scheme 67
3. Turn the drive wheel for the coolant pump in such a way that the fastening screws can be reached through the holes in the belt pulley -arrows-. (Scheme 67)
Scheme 68
4. Pull coolant pump out of the crankcase.
Scheme 69
1. Clean sealing face and install new O-ring on coolant pump.
2. Tighten the 3 fastening screws. --> Tightening torque: 6 ftlb.
3. Fit drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .; then remove the screw from the belt tensioner and tension the belt. Check whether the drive belt is correctly installed.
1. Fill and bleed cooling system according to regulations. > 193817 Draining and filling coolant (includes bleeding)
| Designation | Type | Number | Explanation | |
|---|---|---|---|---|
| Assembly aid | Special tool | P 9627 |
1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)
2. Remove intake-air distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .
Scheme 70
Scheme 71
1 - Thermostat housing (observe loosening and tightening sequence)
2 - Fastening screw M6 x 25
3 - O-rings, 22 x 3, replacing
4 - Coolant pipe for heater
5 - Fastening screw M6 x 16
6 - O-rings, 28 x 3, replacing
7 - Seal for thermostat housing; replacing
8 - Fastening screw M6 x 16
9 - Molded seal; replacing
10 - Thermostat well
11 - O-ring, 50 x 3, replacing
12 - O-ring, 20 x 2.65, replacing
Scheme 72
1. Remove the two coolant lines on the thermostat housing cover. To do this, remove the spring-band clamps and pull off the hoses.
Scheme 73
2. Pull off the cable duct upwards over the coolant pump.
3. Release the upper fastening screw of the oil dipstick.
Scheme 74
4. Loosen the fastening screw on the cable duct.
Scheme 75
5. Disconnect the coolant outlet on the generator. To do this, open the spring-band clamps and pull off the hose. Collect the draining coolant.
Scheme 76
6. Remove the coolant return line on the thermostat housing. To do this, loosen the fastening screw and pull off the line.
Scheme 77
7. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off the plugs.
Scheme 78
8. Undo the 3 rear fastening screws of the heater pipes.
9. Undo the thermostat housing cover. The sequence shown must be observed when doing so.
Scheme 79
Scheme 80
10. Lift the housing cover. Remove the thermostat using assembly aid P 9627 .