Water Pump: Service and Repair

LEGEND
1 Coolant (Water) Pump Pulley Bolt
2 Coolant (Water) Pump Pulley
3 Coolant (Water) Pump Bolt
4 Coolant (Water) Pump
5 O-Ring
6 Throttle Body
7 From Cylinder Head
8 Continued Coolant Circulation Pump
9 Electrical Connector
10 Retaining Clip
11 Engine Coolant Temperature (ECT) Sensor
12 From Heat Exchanger
13 To Heat Exchanger
14 Cap
15 Cover
16 Bolt/Screw
17 Expansion Tank
18 Upper Coolant Hose
19 Lower Coolant Hose
20 Automatic Transmission Fluid (ATF) Cooler
21 Thermostat Housing
22 Coolant Hose
23 Engine Oil Cooler
24 To Cylinder Block
25 Coolant Drain Screw

NOTE: During removal and installation procedures, refer to the component location illustration above and component notes below.

COMPONENT NOTES
Coolant (Water) Pump Pulley Bolt (1)
- Tighten to: 25 Nm (18 ft. lbs.).
- To loosen, use modified holding wrench tool No. VAG 1590, or equivalent.

Coolant (Water) Pump Bolt (3)
- Tighten to: 20 Nm (15 ft. lbs.).

Coolant (Water) Pump (4)
- Check shaft for ease of movement.

O-ring (5)
- Always replace.

Continued Coolant Circulation Pump (8)
- For testing, refer to After-run Coolant Pump.
- Secured with bracket to the camshaft sprocket cover.

Retaining Clip (10)
- Ensure it is seated securely.

Engine Coolant Temperature (ECT) Sensor (11)
- For Climatronic climate control system.
- Color Black.
- 2 pin connector.

Cap (14)
- Check using pressure tester tool No. VAG 1274, or equivalent.
- Test pressure: 1.3-1.5 bar (18.85-21.75 psi)

Bolt/Screw (16)
- Tighten to: 10 Nm (7 ft lbs.).

ATF Cooler (20)

Thermostat Housing (21)
- Refer to Thermostat, Engine Cooling.

Engine Oil Cooler (23)
- Refer to Engine Lubrication found in the Engine section.

Coolant Drain Screw (25)
- Tighten to: 10 Nm (7 ft. lbs.).

REMOVAL
1. Switch off ignition.
2. Disconnect battery ground cable.

NOTE: Obtain the radio anti-theft code from the customer before disconnecting the battery.

3. Disconnect exhaust pipe from the three-way catalyst flange. Service and Repair
4. Drain coolant. Service and Repair
5. Remove ribbed drive belt. Service and Repair
6. Remove intake hose.





7. Pull high tension wires out of ignition coil and unclip from the high tension wiring guide -2-.
8. Remove the high tension wiring guide -2-.
There are 2 other components identified on this image:
- Cover above intake manifold -3-.
- Ignition cable or high tension wiring guide -1-.





9. Pull off vacuum hose between intake manifold upper section and fuel pressure regulator.
10. Remove Intake Air Temperature sensor from intake manifold upper section.
11. Detach coolant expansion tank and place to side; hoses remain connected.





12. Fit engine support bracket tool No. 10-222 A with adapter tool No. 10-222A/3, or equivalent.
13. Locate support bracket in lifting eyes on left and right of cylinder head and take up weight of engine.
14. Detach transmission at left rear assembly mounting and engine at right rear assembly mounting.





15. Detach engine from front engine/trans mount from above.
16. Carefully lift engine.
17. Using a modified coolant pump pulley wrench tool No. VAG 1590, remove coolant (water) pump pulley.

NOTE: If necessary modify coolant (water) pump wrench.

18. Remove coolant pump.

NOTE: To remove and install the coolant pump, push engine by hand slightly to left, to gain clearance for removing and installing.


INSTALLATION
- Installation is the reverse of removal, noting the following:





a. When installing the rear right and front engine/trans mounts, ensure that the recess on the rear right console and the recess on the front console locates on the rubber mount -arrows-.
b. Screw in all bolts on engine/trans mounts by hand approx. 5 to 6 turns.
c. Align engine mounts stress-free by rocking engine assembly.
d. First tighten motor mountings front and rear right, then tighten rear left assembly mounting.
e. Install intake hose.
f. Installing ribbed drive belt.
g. Fill with coolant.





h. Tighten components as shown in the illustration.