Tool Required

999 5443 Puller 999 5444 Press Tool

Removal

1. Drain off approximately 3 liters of coolant. Drain cock is located at left-hand side of car under radiator.

2. Disconnect coolant hose from thermostat housing. 3. Disconnect:

a. Fluid hose clip from dipstick tube. b. Cooling air hose to control module box.

4. Remove drive belt from pump. Use 3/8" ratchet or similar tool to relieve tension on automatic belt tensioner. Remove belt.

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5. Remove guard plate bolt and spacer sleeve. 6. Slacken pressure hose union 1/4 turn. 7. Slacken guard plate lower mounting nut a few turns. 8. Remove pump mounting bolts as follows:

a. 3 bolts through drive pulley holes. b. 2 bolts on left-hand side.

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9. Lift pump straight upward:

a. Collect spillage fluid, if any, in a small container. b. Disconnect pressure hose from pump. Remove original O-ring. c. Carefully make small cut in return hose to free from connection branch.

NOTE: Hose must not be shortened beyond marking stripe at end. Take care to avoid damage to reservoir connection.

d. Raise front end of car so that wheels are free to turn. Turn steering wheel from lock to lock. Use container to collect spillage fluid from return and pressure hoses. Take care to avoid spillage of fluid into generator.

10. Mount pump in vise.

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11. Remove drive pulley. Use puller.

Installation

1. Mount drive pulley. Lubricate pump shaft with fluid. Use press tool.

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2. Remove reservoir mounting clips. Use adjustable pliers and screwdriver. 3. Raise locking tab and remove O-ring.

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4. Assemble reservoir and pump Use new O-ring. Ensure that locking tabs are seated securely.

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5. Install pump:

a. Place protective paper over generator (pump may still contain fluid). b. Install mounting bolts (five). Tighten to 25 Nm (18 ft. lbs.) . c. Install guard plate bolt and spacer sleeve. Tighten to 25 Nm (18 ft.

lbs.) . d. Tighten guard plate lower mounting to25 Nm (18 ft. lbs.) .

6. Install/reconnect:

a. Return and pressure hoses. Fit new O-ring on pressure hose. b. Clip securing hoses to dipstick tube. c. Coolant hose.

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7. Install:

a. Pump drive belt. b. Cooling-air hose to control module box.

8. Top up with coolant. 9. Fill power steering reservoir with fluid and bleed system.

a. Turn steering wheel repeatedly from lock to lock and top up fluid as required.

b. Lower car. c. Apply parking brake and start engine. d. Check fluid level while bleeding system as described below.

A. Turn steering wheel slowly to right and hold in limit position for 10 seconds.

B. Turn steering wheel slowly to left and hold in limit position for 10 seconds.

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e. Repeated steps A and B 20 times. Move car after 10 times to avoid damage to tires.