3•6 Cooling, heating and ventilation systems
7.11 Water pump removed from the timing
cover (B2O2 engine)
7.33 Disconnecting the hoses from the
7.35 Removing the pulley from the water
pump drive flange
4 Remove the plastic moulding and the front
section of the wing liner from under the right-
5 Remove the auxiliary drivebelt(s) as
described in Chapter 1.
6 Unscrew the bolts, and remove the pulley
from the water pump drive flange.
7 Unbolt and remove the auxiliary drivebelt
8 Unscrew the bolt securing the oil cooler
hoses to the timing cover.
9 Unscrew the bolt securing the water pipe to
the cylinder block, and pull the pipe from the
water pump. Remove the O-ring.
10 Loosen the clips and disconnect the hoses
from the water pump.
11 Unscrew the mounting bolts, and remove
the water pump from the timing cover (see
illustration). Remove the gasket.
12 Clean all gasket and sealant from the
contact surfaces of the water pump and timing
13 Ensure that all contact surfaces are clean.
Locate a new gasket on the timing cover.
14 Locate the water pump on the gasket,
then insert the mounting bolts and tighten
them progressively to the specified torque.
15 Reconnect the hoses and tighten the clips.
16 Locate a new O-ring on the water pipe,
and insert the pipe in the water pump. Insert
and tighten the bolt securing the water pipe to
the cylinder block.
17 Insert and tighten the bolt securing the oil
cooler hoses to the timing cover.
18 Refit the auxiliary drivebelt tensioner
pulley, making sure that the plate is located in
the slot in the bracket.
19 Refit the pulley to the water pump drive
flange, then insert the bolts and tighten to the
20 Refit and tension the auxiliary drivebelt(s)
with reference to Chapter 1.
21 Check that the radiator drain plug is tight,
then refit the centre deflector.
22 Refill the cooling system with reference to
23 Run the engine to normal temperature and
check for leaks, then stop the engine.
24 Refit the plastic moulding and the front
section of the wing liner under the right-hand
25• Refit the right-hand front wheel, and lower
the car to the ground.
B204/B234 (balance shaft) engines
26 The water pump is driven by the auxiliary
drivebelt, and is located on the front right-
hand side of the engine.
27 Apply the handbrake, then jack up the
front of the car and support on axle stands
(see "Jacking, towing and wheel changing").
28 Remove the centre deflector from under
the radiator, then drain the cooling system as
described in Chapter 1.
29 Remove the coolant expansion tank from
its mounting. On models up to 1991, unscrew
the bolt; on later models, release the clip.
30 Loosen the clip and disconnect the lower
hose from the expansion tank. Where
applicable, disconnect the engine coolant
level sensor from the expansion tank.
31 Pull on the multi-groove auxiliary drivebelt
so that the automatic tensioner is retracted,
then hold the tensioner in this position by
fitting a home-made tool (see Chapter 1) in the
special slots. Slip the drivebelt from the air
conditioner compressor and water pump
32 Place a piece of cardboard over the oil
cooler and upper radiator crossmember (as
applicable), then disconnect the wiring from
the air conditioning compressor. Unbolt the
compressor and move it to one side without
disconnecting the refrigerant lines - also
remove the bracket.
33 Loosen the clips and disconnect the hoses
from the water pump (see illustration).
34 On Turbo models, remove the lambda
wiring cable clips, then remove the coolant
pipe from the turbocharger and water pump.
35 Unscrew the bolts, and remove the pulley
from the water pump drive flange (see
36 Unscrew and remove the three mounting
bolts securing the top of the water pump to
the timing cover. Note that the upper bolt also
secures the support for the lambda sensor
wiring (see illustration).
7.36 Unscrew the upper water pump
mounting bolt which secures the lambda
7.37a Removing the water pump and sleeve
from the cylinder block
7.37b Releasing the coolant pipe from the
aperture in the water pump