Water Pump: Service and Repair

Coolant Pump

Mount (T40093/5) , from Engine Support Supplement Set (T40093)

Moveable Joint (T40093/4) (Qty: 2), from Engine Support Supplement Set (T40093)

Moveable Joint (T40091/3) (Qty: 2), from Engine Support Basic Set (T40091)

Rail with Holes (T40091/2) , from Engine Support Basic Set (T40091)

Square Pipe (T40091/1) (Qty: 2), from Engine Support Basic Set (T40091)

Engine Support Bridge (10-222 A)

Adapter (10-222 A/28) (Qty: 2)

Shackle (10/222 A/12)

Bracket with Spindle and Hook (10-222 A/10)

Adapter (10-222 A/7)

Support Bracket (10-222 A/31)

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

Adapter (10-222 A/28-1)

Removing

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, 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.

Danger of causing damage to the coupling element.

• Do not bend the coupling element more than 10°.

• Do not stretch the coupling element.

• Do not damage the wire mesh on the coupling element.

- Remove the noise insulation.

- Remove the exhaust system suspended mount bolts - arrows - from the subframe.






- Remove the pendulum support bolt - 1 -.






- Then, remove the bolts - 2 and 3 - and the pendulum support.

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

- Remove the intake hose - 4 - between the throttle valve control module (J338) and air filter. To do so, disconnect the hose - 1 -, if present, and the hose - 2 - (compress the securing ring) and remove the spring clamp - 3 -.






Vehicles with a Automatic Transmission:

- Unclip the transmission control module (J217) - 3 - from the bracket - 7 - and remove it.






- Disconnect the connector - 2 - from the transmission control module.

- Remove the bolts - 1 and 6 -.

- Move the bracket - 7 - with the power steering fluid reservoir to the side. Be careful of the electrical wires - 4 and 5 -.

The hoses remain connected to the power steering fluid reservoir.

Continuation for all Vehicles:






- Remove the battery, the battery tray bolts - arrows - and tray.

- Remove the plenum chamber cover.

- Remove the lines - 1 - from the transport strap - 3 -.






- Remove the transport strap - 3 - from the engine - 2 - and pull it out of the lifting eye - arrow -.

- Install the shackle (10-222 A/12) to this lifting eye.

- Remove the lock carrier trim.

- Remove the bolts - arrows - from the left and right side lock carrier brackets.






- Remove the lower mount from the adapter (10-222 A/28) and replace it with the adapter (10-222 A/28-1).






- Remove the bolts - arrows - from the adapter (10-222 A/28-1).

- Use the bolts from the adapter (10-222 A/28-1) to secure the adapter (10-222 A/28). Do not use the bolts for the lock carrier bracket.






- Bolt - arrows - tightening specification: 8 Nm.

A second technician is needed to install the engine support bridge (10-222 A) to the vehicle in order to prevent the engine support bridge from tipping.

Install the engine support bridge to the engine/transmission subassembly as follows:






1. Adapter (10-222 A/31-2)

2. Moveable joint (T40091/3)

3. Adapter (10-222 A/31-1)

4. Moveable joint (T40093/4)

5. Square pipe (T40091/1)

6. Adapter (10-222 A/28) with adapter (10-222 A/28-1)

7. Bracket with spindle and hook (10-222 A/10)


- Slide the moveable joint (- 2 -) onto the square pipe of the engine support bridge (10-222 A).

• The moveable joint (T40091/3) (- 2 -) bolts on the engine support bridge (10-222 A) face the direction of travel.

- Install the engine support bridge (10-222 A) to the strut towers and have a second technician hold it to prevent it from falling over.

- Slide the left and right square pipes (T40091/1) (- 5 -), forward through the adapters (10-222 A/28) (- 6 -) and position the moveable joints (T40093/4) (- 4 -) on both sides.

- Install the bracket with spindle hook (10-222 A/10) (- 7 -) to the right square pipe (T40091/1).

- Slide the rail with holes (T40091/2) (- 9 -) with the mount (T40093/5) (- 10 -) into the moveable joint (T40093/4) (- 4 -).






1. Adapter (10-222 A/31-2)

2. Moveable joint (T40091/3)

3. Adapter (10-222 A/31-1)

4. Moveable joint (T40093/4)

5. Square pipe (T40091/1)

6. Adapter (10-222 A/28) with adapter (10-222 A/28-1)

7. Bracket with spindle and hook (10-222 A/10)

8. Adapter (10-222 A/7)

9. Rail with holes (T40091/2)

10. Mount (T40093/5)

11. Spindle (10-222 A/11)

12. Shackle (10-222 A/12)


- Insert the locking pin into the rail with holes (T40091/2) (- 9 -) and secure it.

- Tighten all threaded connections on the engine support bridge hand tight. Adjust the height of the engine support bridge parallel over the adapters (10-222 A/28).

- Lengthen the right bracket with spindle and hook (10-222 A/10) (- 7 -) using the adapter (10-222 A/7) (- 8 -).

The hook on the adapter (10-222 A/7) faces downward and will be attached to the cylinder block later.

- Attach the left spindle (10-222 A/11) (- 11 -) to the shackle (10-222 A/12) (- 12 -).






- Position the spindles and hold the engine and transmission. Do not lift.

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






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

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






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

- Remove the 3 coolant pump bolts 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 battery.

Tightening Specifications






• Remove the adapter (10-222 A/7) from the cylinder block.