Removing
Open the hood.
Disconnect the battery terminals.
Note. On vehicles from model year 04 with ESP, each time the battery is disconnected, the steering angle sensor loses its basic setting. It needs to be recalibrated.
Disconnect the ground wire.
Drain the coolant.
Note. On model variant «ECO» remove the engine compartment cover at the bottom.
Substitute the collecting tray.
Open the drain plug (arrow).
Remove the air filter housing 1.
Disconnect the 2 harness connectors, hot film mass air flow meter 3, tank vent valve 2.
Release the tank vent valve.
Dismantle the suction pipe 4.
Loosen 2 nuts.
Dismantle the crankcase ventilation hose 5.
On Z 10 XEP engines: remove the air intake hose.
Release clamp.
Remove the bolt (arrow).
Release the front wheel on the right.
Raise the vehicle.
Remove the front wheel on the right.
Loosen 4 mounting screws.
Raise the vehicle.
Remove the V-ribbed belt cover.
Remove 3 fixing screws 1.
Remove the clip (arrow).
Install tool KM-6169-2 on the gearbox.
Tighten 2 mounting bolts to 95 Nm.
Install tool KM-61691.
KM-6169 fit on the left side of the front axle housing (arrows, fig. I).
The guide pin must be located in the hole in the front axle housing.
Install both holders on the right on the front axle housing (arrows, fig. II).
The guide pin must be located in the hole in the front axle housing (arrow, fig. III).
Tighten the 2 mounting bolts.
Install the support on the KM-6169 tool.
Install mount 2 for the support.
Tighten nut 1.
Adjust the supports.
On the gearbox side, turn the spindles in such a way that the fasteners 3 on the guide pins fit without play.
On the control side of the engine, insert the support trunnion into the bore of the cylinder block without play (arrow)
Tighten nut 1.
Unscrew the engine holder on the right.
Loosen the bolt at the bottom 1.
Lower the car.
Remove the engine holder on the right.
Release the damping block of the engine.
Loosen the 2 fixing screws 1.
Loosen 2 fixing screws (arrows).
Loosen the water pump poly V-belt pulley.
Loosen 3 mounting screws.
Remove poly V-belt.
Note. Mark the direction of rotation and observe the installation position.
Using tool KM-6131, tension the poly V-belt tensioner in the direction of the arrow.
Insert tool KM-61301.
Remove the poly V-belt pulley for the coolant pump.
Loosen 3 mounting screws.
Remove the throttle body heating hose 1.
Remove the hot water supply hose 3 from the coolant pump.
Disconnect the ECT 2 harness connector.
Disconnect radiator hoses 1 and 2 at the top and bottom from the coolant pump.
Release clamps.
Remove coolant pump 1.
Note. When removing, pay attention to the guide bushings.
Remove 9 mounting screws.
Note. Take into account the different lengths of the mounting bolts (arrows - short bolts).
If equipped: remove coolant pump cover 2.
Note. Consider different design options.
Loosen 2 mounting screws.
Remove screw plug 3.
Remove the coolant pipe.
Loosen 3 mounting screws.
Clean the sealing surfaces of the coolant pump, coolant pump cover, coolant pipe, timing case.
Installation
When replacing parts, consider the different design options. Make sure the part numbers are correct.
Install the coolant pipe.
Replace seal.
Tighten 3 mounting bolts to 8 Nm.
Close the screw cap.
Replace O-ring.
Tighten the bolt to 15 Nm.
If equipped: Install the water pump cover.
Replace seal.
Tighten 2 mounting bolts with a torque of 8 Nm.
Install the coolant pump.
Note. Make sure the guide bushings fit correctly (arrows).
Consolidation 1 replace.
Tighten 3 mounting bolts 28 Nm.
Connect the coolant temperature sensor harness connector.
Install the radiator hose at the bottom.
Fasten the clamp.
Install the radiator hose at the top.
Fasten the clamp.
Install the hot water supply hose.
Install the throttle body heater hose.
Fasten the clamp.
Flange the poly V-belt pulley of the coolant pump.
Tighten 3 mounting bolts.
Install poly V-belt.
Note. Observe direction of rotation and installation position.
Tension the V-ribbed belt tensioner using tool KM-6131.
Take out the KM-6130 tool.
Loosen the tension of the V-ribbed belt tensioner.
Attach the V-ribbed belt pulley to the coolant pump.
Tighten the 3 mounting bolts with a tightening torque of 20 Nm.
Install the motor holder on the right.
Insert the bolt at the bottom.
Tighten the 2 mounting bolts at the top to 60 Nm.
Attach the engine shock absorber.
Tighten 2 mounting bolts to 40 Nm.
Raise the vehicle.
Fasten the motor holder on the right.
Bolt at the bottom tighten 60 Nm.
Remove the 2 engine and transmission control side supports.
Remove fixtures.
Close the coolant drain plug.
Install the V-ribbed belt cover.
Tighten the 3 mounting bolts.
Install the clamp.
Lower the car.
Note. On model variant «ECO» install the engine compartment cover at the bottom.
Install the front wheel on the right.
Tighten 4 mounting bolts.
Lower the car.
Fasten the front wheel on the right.
Tighten 4 mounting bolts to 110 Nm.
Install the air filter housing.
Tighten the bolt.
Attach the suction pipe.
Replace O-ring.
Tighten 2 nuts.
On Z 10 XEP engines: Install the air intake hose.
Tighten the clamp 3.5 Nm.
Install the crankcase ventilation hose.
Connect the tank vent valve.
Connect the 2 wire harness connectors.
Connect the battery terminals.
Fill and bleed the cooling system.
Program the volatile memory.
Close the hood.
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