Water Pump: Service and Repair

Coolant Pump

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)

• Engine Support Basic Set (T40091)

• 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, 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 and the battery tray.


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 the generator, power steering pump and coolant pump ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

- Remove the 4 exhaust manifold to front exhaust pipe nuts - 2 - and 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 bolt - 1 -.






- Then, remove the bolts - 2 and 3 - and 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:

- Remove the plenum chamber cover.

- Remove the radiator grille.

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






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

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

- Install the engine support bridge (10-222 A) , support the engine with the transmission.






1. (T40091/3)

2. (T40091/1)

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

4. Shackle (10-222 A/12)

5. Bracket (10-222 A/31-4)

6. Support (10-222 A/31-3)

7. Engine support adapter (10-222 A/3)

8. Adapter (10-222 A/7)

9. Support (10-222 A/31-2)

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


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

- Attach the adapter (10-222 A/7) to the cylinder block.






- Preload the right spindle.

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






- Remove the bolts - 5 - and set the coolant expansion tank with the hose 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 as possible.

- Remove the 3 coolant pump bolts => [ (Item 26) 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