Water Pump: Service and Repair

Coolant Pump

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222A)

• Engine Support Adapter (10-222A/3)

• Engine Support Feet (10-222A/8)

• Shackle (10-222A/12)

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

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

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

• Route all lines and wires in their original locations.

• Make sure there is enough clearance to moving or hot components to prevent damage to the lines.

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

CAUTION!
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 ] Draining and Filling.

- Remove intake tube - 4 -. To do so, disconnect hoses - 1 and 2 - (compress securing ring) and remove spring clamp - 3 -.





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

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

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





- Remove the front exhaust pipe - 1 - from the manifold and tie up firmly 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.

With a Manual Transmission

- Remove the selector mechanism from transmission..

With a Automatic Transmission

- Remove the selector lever cable from transmission.

Positioning the (10-222A), Rabbit from MY 2004

- Position the (10-222A) with the (10-222A/8 ). Support the engine/transmission assembly in the installed position using the (10-222A/3) and (10-222 A/12).





• Illustration shows the arrangement with a automatic transmission.

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

Positioning the (10-222A), Golf from MY 2010





- Position the (10-222A) with the (10-222A/8 ). Support the engine/transmission assembly in the installed position as shown.

Note the following:

• The plate - A - must not be bent.

• Secure the (10 - 222A/12) on the reinforcing brace in vehicles with a manual transmissions and at the transport eye in vehicles with a automatic transmissions.

Continuation for All

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





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

- Remove the bolts - 5 - and place the coolant expansion tank on top of the engine with the hoses connected.

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





The rear bolt in the cylinder block is accessible above wheel housing liner.

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





- Slide the engine as far as possible toward the front left

- Remove the 3 bolts - item 23 -=> [ Bolt ] Cooling System Components, 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. Sealing plug in housing points downward.

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

• Install the battery.

Tightening Specification