Peugeot 205 Manual

Coolant pump - removal and refitting
Cooling, heating and air conditioning systems / Coolant pump - removal and refitting


Note: Refer to the warnings given in Section 1 of this Chapter before proceeding.

XV, XW, and XY series engines Removal
1 Drain the cooling system and remove the auxiliary drivebelt as described in Chapter 1.

2 Disconnect the radiator bottom hose, heater return hose, and inlet manifold return hose from the coolant pump (see illustration).

8.2 Radiator and heater hose connections on the coolant pump - XV, XW and XY
8.2 Radiator and heater hose connections on the coolant pump - XV, XW and XY series engines

For better access, remove the air cleaner and inlet cowl, with reference to the relevant Part of Chapter 4.

3 Unscrew the mounting bolts and remove the coolant pump from the cylinder block.

Remove the O-ring (see illustrations).

8.3a Undo the mounting bolts . . .
8.3a Undo the mounting bolts . . .

8.3b . . . withdraw the pump from the cylinder block . . .
8.3b . . . withdraw the pump from the cylinder block . . .

8.3c . . . and recover the O-ring - arrowed (XV, XW and XY series engines
8.3c . . . and recover the O-ring - arrowed (XV, XW and XY series engines

4 If the coolant pump is worn, noisy or leaks coolant it must be renewed, as repair is not possible. However, if either of the half casings is individually damaged it may be renewed, together with the central gasket.

Refitting
5 Refitting is a reversal of removal, bearing in mind the following points: a) Renew the pump O-ring.

b) Refit the auxiliary drivebelt and refill the cooling system as described in Chapter 1.

XU series engines
Removal
6 Drain the cooling system (Chapter 1).

7 Remove the timing belt and tensioner, as described in Chapter 2B.

8 Remove the plastic shield, noting the locations of the different types of bolt (see illustration).

8.8 Timing belt inner plastic shield and special bolt locations on early XU
8.8 Timing belt inner plastic shield and special bolt locations on early XU series engines

Apply sealant to bolt threads A

9 Unscrew the five mounting bolts and remove the coolant pump from the cylinder block. Remove the gasket (see illustration).

8.9 Coolant pump assembly fitted to XU series engines
8.9 Coolant pump assembly fitted to XU series engines

1 Gasket
2 Coolant pump

10 If the coolant pump is worn, noisy or leaks coolant it must be renewed, as repair is not possible.

Refitting
11 Refitting is a reversal of removal, bearing in mind the following points: a) Thoroughly clean the mating faces and use a new gasket.

c) Refit and tension the timing belt as described in Chapter 2B.

d) Refill the cooling system (Chapter 1).

TU series aluminium block engines
Removal
12 Drain the cooling system as described in Chapter 1.

13 Remove the timing belt as described in Chapter 2C.

14 Unscrew the nut from the right-hand engine mounting.

15 Using a trolley jack and block of wood, lift the right-hand side of the engine as far as possible.

16 Unscrew the nuts and remove the engine mounting bracket from the coolant pump housing.

17 Disconnect the hoses from the housing, then unbolt the housing from the block.

Remove the O-ring seal (see illustrations).

8.17a On TU series aluminium block engines, disconnect the hoses (arrowed)
8.17a On TU series aluminium block engines, disconnect the hoses (arrowed) from the coolant pump housing

8.17b . . . then undo the bolts (arrowed) and remove the housing from the
8.17b . . . then undo the bolts (arrowed) and remove the housing from the block

18 Unbolt the coolant pump from the housing, and remove the O-ring (see illustrations). If necessary, similarly remove the inlet elbow.

8.18a With the housing removed, undo the bolts and remove the coolant pump .
8.18a With the housing removed, undo the bolts and remove the coolant pump . . .

8.18b . . . then recover the O-ring seal (arrowed)
8.18b . . . then recover the O-ring seal (arrowed)

19 If the coolant pump is worn, noisy or leaks coolant it must be renewed, as repair is not possible.

Refitting
20 Refitting is a reversal of removal, bearing in mind the following points: a) Renew the O-rings.

b) Make sure that the housing-to-block location dowels are in position.

c) Refit and tension the timing belt as described in Chapter 2C.

d) Refill the cooling system as described in Chapter 1.

TU series cast-iron block engines Removal
21 Drain the cooling system as described in Chapter 1.

22 Remove the timing belt as described in Chapter 2C.

23 Unscrew the two securing bolts, and withdraw the coolant pump from the cylinder block (see illustration). Recover the O-ring.

8.23 Coolant pump securing bolt (arrowed) on TU series cast iron block
8.23 Coolant pump securing bolt (arrowed) on TU series cast iron block engines

24 If the coolant pump is worn, noisy or leaks coolant it must be renewed, as repair is not possible.

Refitting
25 Refitting is a reversal of removal, bearing in mind the following points.

a) Renew the pump O-ring.

b) Refit and tension the timing belt, as described in Chapter 2C.

c) Refill the cooling system (Chapter 1).


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