Water Pump: Service and Repair

Coolant Pump

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Engine Support Adapter (10-222 A/3)

• Engine Support Feet (10-222 A/8)

• Shackle (10-222 A/12)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)


When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant and refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover with Air Filter.

- Remove the battery.

- Open the cover - 1 - for the E-box and remove the wire - 2 -.






- Remove the bolts - arrows - and remove the battery tray from the vehicle.


Hot steam may escape when opening the expansion tank cap.

• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.

• Cover the cap with a cloth and open very carefully.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the air guide bolts - arrows - from the lock carrier.






- Remove the connecting pipe - 4 -. To do so, disconnect the pressure and vent tubes - 1 and 2 - (compress the securing ring) and remove the spring clamp - 3 -.






- Remove front and rear sections of the right front wheel housing liner.

- Remove the generator and coolant pump ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

- Remove the 4 exhaust manifold to front exhaust pipe nuts - 2 - and the exhaust system suspended mount bolts - 3 -.






- Remove the exhaust pipe - 1 - from the manifold and secure it to the side. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe with Catalytic Converter.

• The flex joint in the front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.

- Remove the pendulum support.

Vehicles with a Manual Transmission:

- Remove the shift mechanism from the transmission.

Vehicles with a Automatic Transmission:

- Remove the selector lever cable from the transmission.

Continuation for all Vehicles:

- Install the engine support bridge (10-222 A) with the engine support feet (10-222 A/8) and support the engine/transmission in its installed position using the engine support adapter (10-222 A/3) and the shackle (10-222 A/12).






• Illustration shows the arrangement with a automatic transmission.

• In vehicles with a manual transmission, the spindle - A - is to be located toward the rear and secured to reinforcement brace of the transmission.

- Remove the bolt - 2 - and place the windshield washer reservoir - 1 - toward the front.






- Remove the bolts - 6 - and disconnect the connector - 3 -.

- Remove the bolts - 5 - and set the coolant expansion tank with hoses connected onto the engine.

- Remove the bolts - 1, 2 and 3 - and remove the engine mount.






• The rear bolt - 2 - is accessible through a hole in the wheel housing.

- Remove the transmission mount to transmission mount bracket bolts - arrows -.






- Slide the engine forward and to the left as far possible.

- Remove the 3 coolant pump bolts => [ (Item 23) Bolt ] Cooling System Components Overview, Engine Side and swivel the coolant pump - A - out as shown.






Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Note the installed position of the coolant pump. The sealing plug in the housing points downward.

• Fill the coolant. Refer to => [ Draining and Filling ] Procedures.

• Install the battery.

Tightening Specifications