Cooling System - Leaks From The Auxiliary Coolant Pump
ConditionSupercedes 19-05-05, Oct. 28, 2005 Change of applicable Model Years
^ Coolant leakage around Auxiliary Coolant Pump.
^ Coolant light may be illuminated.
19 06 02 5/8/2006, 2010725/3 Supersedes Technical Bulletin Group 19 number 05-05, dated October 28, 2005 due to model year update.
Technical Background
Auxiliary Coolant Pump (located under intake manifold) may be leaking coolant from pump body.
Production Solution
N/A
Service
For vehicles of MY 2002 and higher there is a Repair Kit, which needs to be installed as follows:
Repair Procedure:
Prior to installing the NEW auxiliary coolant pump parts kit, the OLD leaking pump needs to be removed.
Auxiliary coolant pump, removing:
^ Drain coolant and remove auxiliary coolant pump located under intake manifold (see repair manual repair group 19).
^ Install angled elbow -1- instead of removed auxiliary coolant pump as shown
^ Install spring clamps -arrows- as shown.
^ Move existing electrical connector of old auxiliary coolant pump (harness interface) to outside of the valley (rear).
^ Connect NEW Harness Adapter to existing harness interface.
For MY 2002 Vehicles:
If electrical connectors between harness adapter and existing engine harness interface do not match:
Connector housing of engine harness interface needs to be replaced with Part No 8D0 971 946 (use Wiring Harness Repair Kit, Part No: VAS 1978).
^ Secure connected harness with 2 Tie Wraps -arrows- as shown.
^ Position and Secure NEW harness adaptor with (qty 3) Tie Wraps -arrows- as shown.
NEW auxiliary coolant pump, installing:
^ Assemble NEW auxiliary coolant pump -2- and Bracket -1-.
^ Hook rubber mount of pump in lower bow of bracket -arrow- first and tighten bolt -3- Part No: N 101 244 08 to a torque of 9 Nm.
^ Install 2 coolant hoses onto fittings of coolant pump as shown.
Adjust coolant hoses so that the position mark of each hose is in line with position mark of pump fittings -arrows-.
^ Secure coolant hoses with 2 NEW spring clamps (included in kit).
Tip:
Locking tab of each spring clamp must be located in center of X-mark of each coolant hose (arrows).
^ Remove lower pressure hose to charge air cooler (right side).
^ Disconnect coolant hose -arrow- from thermostat housing port.
^ Disconnect electrical connector from thermo switch on lower end of coolant hose to radiator -arrow-.
^ Remove coolant hose (release clamp -arrow-).
^ Install shrink tubing (Part No:078 121 092) onto coolant hose as shown in cross section.
^ Carefully heat the shrink tubing-i-using heat gun until it is firmly attached to coolant hose (wiring harness repair kit Part No: VAS 1978 contains a heat gun)
^ Re-install coolant hose between thermostat housing and radiator.
^ Remove coolant hose -1- from thermostat housing to front water pipe.
Tip:
Save both spring clamps to be used later.
^ Install auxiliary coolant pump assembly in place of removed coolant hose.
^ Use 2 original spring clamps which were used for installation of the removed coolant hose.
Tip:
The spring clamps need to be pre-installed onto the coolant hoses prior to connecting the coolant hoses to fittings.
^ Install the 2 coolant hoses of auxiliary coolant pump assembly onto fittings of thermostat housing and front water pipe as shown.
^ Ensure that coolant hoses have clearance from surrounding components (adjust if necessary).
^ Secure coolant hoses with spring clamps-arrows- (position locking tabs of spring clamps as shown -arrows-).
^ Fasten auxiliary coolant pump bracket to Alternator bracket (see illustration) using self cutting screw -1- Part No: N 100 835 02 (tighten screw to a torque of 9 Nm
^ Connect harness adapter to electrical connector -2- of auxiliary coolant pump (see illustration).
^ Position and secure NEW harness adapter with (qty. 2) Tie Wraps -arrows- as shown.
^ Re-install all components which were removed for repair.
^ Refill coolant as necessary.
Warranty
Required Parts and Tools
Parts Requirements:
Tip
Individual components of the auxiliary coolant pump repair kit Part No: 078 998 998, which may be replaced separately, consist of the following:
Special Tool Requirements:
^ Pliers for spring clamps: VAS 5024 A
^ Wiring Harness Repair Kit: VAS 1978