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 (VAG 1331)

• Torque wrench 40-200 Nm (VAG 1332)

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 (e.g. fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires 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..

- Open the cover - 1 - for the E-box and remove the wire - 2 -.





- Remove the bolts - arrows - and remove the battery holder 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 cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.

- Remove the air guide bolts - arrows - from the lock carrier.





- Remove the intake hose - 4 -. To do so, disconnect the air hoses - 1 - and - 2 - (compress securing ring) and remove the 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 nuts - 2 - and bolts - 3 -.





- Remove the exhaust pipe - 1 - from the exhaust 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 degrees, otherwise it may be damaged.

- Remove the pendulum support.

With Manual Transmission

- Remove the shift mechanism from the transmission..

With Automatic Transmission

- Remove the selector lever cable from the transmission.

Continuation for All

- Install the (10-222A) with (10-222A/8) and support the engine/transmission assembly in the installation position using the (10-222A/3) and the (10-222A/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.

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





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

- Remove the bolts - 5 - and set down the coolant expansion tank with connected hoses onto the engine.

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





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

- Remove the transmission side engine mount bolts - arrows -.





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

- Remove the 3 coolant pump bolts and rotate the coolant pump - A - out as shown.





Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Note installation position of coolant pump. Sealing plug in housing points downward.

• Fill the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.

• Install the battery.

Tightening Specifications