Unable to remove water pump V40 D4 5cyl 2.0 diesel (D5204T4)
 

Hi All,

I'm replacing the cam belt and waterpump on a 2104 V40 D4 with the 5 cylinder 2.0 diesel engine, and am struggling to remove the water pump. There is not enough clearance between the chassis leg and engine block to remove it, nor the cam belt rear cover. I've tried the usual trick of removing the engine mounts and jacking and lowering the engine, but no joy.

I used to be able to access VIDA for the workshop manual, but that is no longer an option, unfortunately.

Has anybody done the job on this engine/chassis combination successfully before? If so, how did you manage to remove the water pump, please?

Cheers.

Just in case anyone else is struggling with the same issue...

** I accept no responsibility if this doesn't work for you, you hurt yourself, or damage your vehicle etc. I am NOT recommending that you do this, it is merely details of how I did it **


I managed to get the water pump out by doing the following:

Remove air filter housing and pipework
Remove battery and battery tray
Loosen driveshaft bolts on both sides and make sure the shafts are free to move in the hubs
Disconnect ball joint on N/S lower control arm (to allow strut to move outboard)
Use 2 trolley jacks (one under gearbox and one under sump, next to the crank pulley). The trolley jacks should be orientated to allow the engine to move sideways.
BE CAREFUL that the engine doesn't tip over towards the front or rear of the car whilst continuing!
Remove all (yes, ALL) engine mounts
Raise the crank pulley end and lower gearbox end, making sure that no pipes/wires etc foul on anything
Push engine towards the N/S of the car

This will finally allow you to remove the back cam belt cover and water pump from the car.

you don't need to replace the water pump on these, they last forever as long as they don't leak or have rough feeling when turning. I have never come across a faulty one since they were introduced on the 960 33 years ago in my experience working on them professionally! .