Latest revision as of 08:28, 10 August 2010

Removal

1. Open the radiator drain plug and drain out the coolant. Remove the lid of the expansion tank to speed up the draining.
2. Remove the air cleaner housing.
3. Undo the intake hose and plug the pipe (turbo).
4. Remove the bypass hose and remove the pressure pipe between the charge air cooler and the throttle body (turbo).
5. Release the tension on the belt tensioner with a 1/2" square extension bar and place a 6 mm drill in the hole.
6. Undo the steering servo pump with its console and hang it up on the radiator crossmember.
7. Undo the coolant hoses and the pipes on the pump.
8. Undo the screw which holds the coolant pipe in the engine's front left-hand corner.
9. Remove the hose to the throttle body from the coolant pipe and undo the screws on the thermostat housing. Move the pipes to one side.
10. Remove the boost pressure control valve and move it to one side (turbo).
11. Remove the coolant pump.
12. Remove the sleeve with the O-rings and remove the coolant pump from the pump housing.

Fitting

1. Clean the sealing surfaces and fit the coolant pump to the pump housing.
2. Lubricate the O-rings with an acid-free vaseline and fit the sleeve together with the pump.
3. Refit the boost pressure control valve (turbo).
4. Refit the coolant hose to the throttle body and refit the screws on the thermostat housing.
5. Refit the screw which holds the coolant pipe to the front left-hand corner of the engine.
6. Reconnect the coolant hoses and pipes to the coolant pump.
7. Refit the steering servo pump with its bracket and put the belt back.
8. Relieve the belt tensioner of strain, using a 1/2" square extension bar, and remove the drill.
9. Refit the pressure pipe between the charge air cooler and the throttle body and refit the bypass hose (turbo).
10. Refit the intake hose (turbo) and refit the air cleaner.
11. Make sure that the radiator drain plug is screwed in tight. Fill with coolant and check the system for leaks.