MBE 900 – Section 4.3 Coolant Pump – EGR Engine

Section 4.3
Coolant Pump – EGR Engine

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Section 4.3.1
Coolant Pump Removal – EGR Engine

Remove the coolant pump as follows (see Figure "Coolant Pump and Related Components EGR Engine" for component location):‪

1. Upper Thermostat Housing‪	5. Coolant Pump‪
2. Lower Thermostat Housing‪	6. Crankshaft Damper‪
3. Connector Tube‪	7. Belt Tensioner‪
4. Pulley‪	8. Cab Heater Tube‪

Figure 1. Coolant Pump and Related Components EGR Engine

HOT COOLANT ‪
To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.‪

1. Drain engine coolant.
2. Remove the fan and fan shroud from the vehicle.
3. Release the tension on the poly-V belt tensioner (7) and remove belt. See Figure "Coolant Pump and Related Components EGR Engine" .
4. Remove the pulley mounting bolts and pulley (4). See Figure "Coolant Pump and Related Components EGR Engine" .
5. Remove EGR delivery pipe. Refer to "10.9.1 EGR Delivery Pipe Removal" .
6. Remove EGR coolant inlet tube. Refer to "10.7.1 EGR Coolant Inlet Tube Removal" .
7. Remove EGR coolant return tube. Refer to "10.8.1 EGR Coolant Return Tube Removal" .
8. Remove charge air intake housing. Refer to "10.3.1 EGR Charge Air Intake Housing Removal" .
9. Remove engine trim panel.
10. Remove two bolts and spacers from charge air housing support bracket.
11. Remove engine valve cover. Refer to "1.1.1 Cylinder Head Cover Removal" .
12. Remove three bolts securing heater supply tube (8). Remove tube and discard seal ring. See Figure "Coolant Pump and Related Components EGR Engine" .
13. Disconnect temperature sensor connector on thermostat housing. If required remove temperature sensor from housing.
14. Remove three bolts securing thermostat housing (2) and remove housing and gasket. Discard gasket. See Figure "Coolant Pump and Related Components EGR Engine" .
15. Remove water connector tube (3) from thermostat housing (2) and discard tube. See Figure "Coolant Pump and Related Components EGR Engine" .
16. Remove banjo bolt and washers from air compressor coolant line on pump (5). Discard washers.
17. Remove hexagon socket-head bolt from belt tensioner (7) and remove tensioner. See Figure "Coolant Pump and Related Components EGR Engine" .
18. Remove banjo bolt and two washers from rear of oil filter housing going to turbocharger. Discard washers. See Figure "Coolant Pump and Related Components EGR Engine" .
19. Remove bolts securing coolant pump (5) and seal ring to rear housing of coolant pump and remove. Discard seal ring.See Figure "Coolant Pump and Related Components EGR Engine" .

    Note: The oil filter is part of the rear coolant pump housing and must be removed as an assembly.

    Note: Only five bolts can be removed during the removal of the rear coolant pump housing and oil filter assembly due to interference with damper. Loosening the bolt near the damper completely will allow remove of assembly.

20. Unscrew the oil filter to allow oil in the canister to drain back into the engine prior to removing.
21. Remove six bolts securing coolant pump (5) and oil filter assembly to the cylinder block. Discard two seals on rear of housing. See Figure "Coolant Pump and Related Components EGR Engine" .

Section 4.3.2
Coolant Pump Installation – EGR Engine

Install the coolant pump as follows (see Figure "Coolant Pump and Related Components EGR Engine" for component location):‪

1. Install two new seals on rear of coolant pump (5) and oil filter assembly. See Figure "Coolant Pump and Related Components EGR Engine" .

   Note: One lower bolt, near the damper, must be installed in rear coolant pump and oil filter assembly prior to installation due to interference by damper.

   Note: The oil filter is part of the coolant pump housing and must installed as an assembly.

2. Secure the coolant pump housing and oil filter assembly to the cylinder block with six bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft).

   Note: The belt tensioner has two locating pins on the rear that must align with corresponding holes in the cylinder block.

3. Install the hexagon socket-head bolt in the belt tensioner (7) and secure to cylinder block. Tighten bolt to 50 N·m (37 lb-ft). See Figure "Coolant Pump and Related Components EGR Engine" .
4. Install the banjo bolt and two new washers and secure water tube to the coolant pump.
5. Install a new seal ring on the heater supply tube (8) and secure tube to coolant pump with three bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "Coolant Pump and Related Components EGR Engine" .
6. Install a new gasket and secure the thermostat housing to the coolant pump with three bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft).
7. Connect temperature sensor electrical connector at thermostat housing.
8. Install the banjo bolt and two new washer and secure tube on rear of oil filter housing going to turbocharger.
9. Install engine valve cover. Refer to "1.1.2 Cylinder Head Cover Installation" .
10. Install the charge air housing bracket, two bolts and spacers and secure bracket to cylinder head.
11. Install the engine trim panel.
12. Install charge air intake housing. Refer to "10.3.2 EGR Charge Air Intake Housing Installation" .
13. Install EGR coolant return tube. Refer to "10.8.2 EGR Coolant Return Tube Installation"
14. Install EGR coolant inlet tube. Refer to "10.8.2 EGR Coolant Return Tube Installation" .
15. Install EGR delivery pipe. Refer to "10.9.2 EGR Delivery Pipe Installation" .
16. Install pulley and secure with bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft).
17. Release the belt tensioner. Route the poly-V belt around the fan pulley and restore belt tension.
18. Install the fan blade and fan shroud on the vehicle then position the fan shroud on the radiator. Tighten the fan shroud mounting bolts until firm.
19. Fill the engine with removed coolant, and check and test for leaks. Refer to "10.5.2.1 Testing Engine for Leaks" .