Withdrawal
1. Drain the coolant.
2. Loosen the mounting screws and remove the lower and right side covers of the engine compartment (arrow illustration). The illustration shows the version with a petrol engine. Removing the bottom cover of a diesel engine is discussed in subsection Removal and installation of the bottom cover of an impellent compartment.
3. Remove the coolant pump drive V-belt, refer to subsection Removing and installing ribbed V-belt.
4. Loosen the 3 hex socket screws and remove the tensioner from the holder.
5. Set the piston of the first cylinder to TDC. Loosen the tension of the toothed belt and remove it only at the top from the camshaft pulley, refer to subsection Removal, installation and tension of a toothed belt.
Warning: Vibration damper and lower belt cover do not need to be removed.
6. To protect the toothed belt from escaping coolant, cover the belt with a rag.
Gas engine
7. Engine 150 HP: Turn away bolts of fastening and remove a broad tank. Take it aside with the hoses attached. Remove the charge air pipe near the coolant pump by loosening the clamps.
8. Engines 1.6 l: Turn out bolts -1- and -5- and remove a back protective cover of a gear belt -2-.
9. All engines: Unscrew the 3 coolant pump mounting bolts -4- and remove it by carefully pulling it out along the engine support. Remove sealing ring -3-.
10. Remove the toothed belt covers.
Installation
11. Thoroughly clean the sealing surfaces for the ring.
12. Moisten a new O-ring with coolant and install.
13. Install the coolant pump. Installation position for all engines: The plug in the housing points down.
14. Engine 1.6 l: Reinstall the rear toothed belt guard. Tighten bolt -1- to 20 Nm, refer to illustration.
15. Fasten the coolant pump with three bolts to a torque of 15 Nm.
16. Establish a gear belt, at the same time address to subsection Removal, installation and tension of a toothed belt.
17. Fasten the V-belt tensioner with three hexagon socket screws to 25 Nm.
18. Install the V-belt, while referring to subsection Removing and installing ribbed V-belt.
19. Fill the system with coolant, while referring to the relevant subsection.
20. Engine 150 HP: Attach the expansion tank. Insert the charge air pipe in the area of the coolant pump, secure the clamps.
diesel engine
21. Disconnect fuel hoses (arrows accompanying illustration) at the injection pump. To do this, open the clamps and slide them back. Seal the fuel hoses with, for example, polyethylene and rubber rings to prevent dirt from entering the system.
22. Disconnect the connector -2 - of the suction pipe temperature/pressure sensor.
23. Remove the air supply pipe -1- by loosening the clamps.
24. Remove the lower air supply pipe -2- by loosening the bolts -1- and -3-.
25. Remove the toothed belt from the camshaft pulleys and injection pump, refer to subsection Setting the piston of the first cylinder to TDC.
26. Disconnect the deflecting roller -2-.
27. Remove the fixing bolt -1- of the deflection roller and press the roller about 30 mm down.
28. Unscrew the 3 mounting bolts -3- of the coolant pump -4- and carefully remove it. Remove sealing ring -5-.
Installation
29. Thoroughly clean the area under the O-ring.
30. Moisten the new O-ring with coolant and install it in place.
31. Install the coolant pump. Position of the pump: the plug in the housing must point down.
32. Fasten the pump with three bolts to a torque of 15 Nm.
33. Fix deflector roller with new bolt -1-. Tighten the bolt first to a torque of 40 Nm, then tighten the bolt with a hard wrench at an angle of 90° (1/4 turn).
34. Install toothed belt, refer to subsection Setting the piston of the first cylinder to TDC.
35. Tighten the 3 screws securing the tensioner to 25 Nm.
36. Fasten the air pipe to the holder, fasten the clamps.
37. Install the V-belt, refer to subsection Removing and installing the V-belt.
38. Fill the system with liquid, refer to subsection Coolant replacement.
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