Water Pump: Service and Repair
Coolant Pump
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Engine and transmission jack (VAG 1383A)
• Spring type clip pliers (VAS 5024A) or hose clip pliers (VAS 6340)
• Step ladder (VAS 5085)
• Engine holder bracket (T03000)
• Hose clamps up to 25 mm dia. (3094)
• Old oil collecting and extracting device (VAG 1782)
• Adapter set for engine and transmission support (VW 540/1 A)
• M8 x 100 bolt
• Cable tie
• To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand.
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
CAUTION!
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.
- Remove the intake hose - 1 - and connector - 2 - from the Mass Air Flow (MAF) sensor.
- Disconnect the hose - 3 - from the air filter housing.
- Remove the bolts - 4 and 6 - and remove the air filter housing.
- Remove the battery.
- Remove the battery holder bolts - arrows - and holder.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the rear bolt - arrow - for the engine mount through the wheel housing.
- Remove the pendulum support bolts - arrows -.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Bring the lock carrier into service position. Radiator Support
- Support the lock carrier using a sleeve - B -, 80 millimeters (mm) in length, for example, from (VW 540/1 A) and a M8 x 100 bolt - A -.
- Empty the power steering reservoir using (VAG 1782) and remove it.
- Remove the bracket nuts - 2 - for the power steering reservoir.
- Remove the nut - 1 - from the bracket. To do so, remove the right main head lamp.
- Disconnect the intake line from the power steering pump. Seal the pump and line with clean plugs.
- Remove the nut - arrow - for the intake line - A - at the engine mount. Remove the intake line.
- Only slightly loosen the bolts for the engine and transmission mounts at the subframe (less than 1 rotation).
- Install the (T03000) as follows:
• Remove pin (T03000/1) from (T03000).
• Install the (T03000) to the cylinder block with pin - 3 - and tighten the bolts - 1 and 2 - hand tight.
• Then install pin (T03000/1) and tighten to 20 Nm.
• Then tighten bolts - 1 and 2 - to 25 Nm.
- Place the (T03000) on the (VAG 1383A) and lift the engine/transmission assembly slightly.
- Remove the engine mount bolts - arrows - from above and remove.
• Use (VAS 5085) to remove the bolts.
- Remove both front bolts from the holding fixture.
- Remove the transmission mount bolts - arrows - from above.
- Carefully lower the engine with transmission only as far downward - arrow 2 - until pin - 4 - of transmission mount bracket can be slid toward the left - arrow 3 - out from under the transmission mount.
- Slide the engine/transmission assembly until it stops at left longitudinal member.
- Rotate the pulley so that arrow - A - (relative to engine axis) points upward vertically.
- Remove the coolant pump bolts - arrows -.
- Pull the coolant pump - A - out of the cylinder block.
- Guide the coolant pump - A - through between the longitudinal member and cylinder block and remove it.
Installing
Installation is performed in the reverse order of removal. When doing this note the following:
CAUTION!
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.
Note the installed position of coolant pump before installing.
- Rotate the pulley so that the arrow - A - (relative to engine axis) points upward vertically. Holes in the pulley must align opposite the bolts - arrows -.
- First, firmly bolt the engine mount to the engine, then align the engine/transmission assembly free of tension via a shaking motion and tighten the bolts to the subframe.
• Tightening specifications for the engine and transmission mounts. Refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.
- Install the lock carrier.
- Install the bracket for the reservoir and power steering line.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the battery.
- Fill with coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Install noise insulation.
- Fill the power steering system with hydraulic oil.
- Install the battery.
Tightening Specifications
