Volkswagen Workshop Service and Repair Manuals

Removing and installing coolant pump

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

t	Cooling system charge unit -VAS 6096-

t	Adapter for cooling system tester -V.A.G 1274/8-

t  Refractometer -T10007 A-

t  Torque wrench -V.A.G 1331-

t  Torque wrench -V.A.G 1410- Removing –  Drain coolant → Chapter. –  Pull hose -1- off air filter housing.

–  Pull air filter housing upwards off studs at positions -2- and -3-. –  Push air filter housing and intake connecting pipe in -direction of arrow- out of mounting -4-. –  Remove air filter housing from engine compartment.

–  Unscrew securing bolts -arrows- of cover -1-. –  Unclip line guide from cover. –  Take off cover -1-.

–  Disconnect all coolant hoses -1- from coolant pump.

–  Remove retaining ring -arrow- of gear selector cable. –  Remove gear selector cable -1- from selector lever and lay to side.

–  Unscrew securing bolts -1- through -5- of coolant pump in sequence given. –  Remove coolant pump and thermostat housing. If the coolant pump is to be renewed: –  Remove thermostat housing → Chapter. Installing Install in reverse order. In the process, note the following: –  If coolant pump has been renewed, install thermostat housing → Chapter.

–  Ensure proper seating of gaskets -arrows-. –  Moisten gasket with coolant.   Caution Always adhere to the sequence of work steps given below when installing the coolant pump. This ensures that the toothed belt is correctly tensioned. The following work steps should be carried out with the aid of a 2nd mechanic. –  Fit toothed belt centrally onto camshaft sprocket and coolant pump toothed belt pulley. –  Mount coolant pump on cylinder head with securing bolts. –  First tighten securing bolts in sequence -1- to -5- to 10 Nm.

–  Then, loosen all bolts by 180°.

–  Using hexagon on coolant pump, preload coolant pump to 35 mm using 10 mm hexagon socket -6-, universal joint, extension and torque wrench -V.A.G 1331-. –  Keep torque wrench -V.A.G 1331- pushed to that torque. –  Support extension and universal joint with other hand. –  Tighten securing bolts -1- through -5- clockwise in sequence given to 12 Nm. –  Install selector mechanism to gearbox → Rep. gr.34. –  Replenish coolant → Chapter. –  Install air filter housing → Chapter.

Specified torque:

Component	Specified torque
Thermostat housing to coolant pump	7 Nm
Coolant pump	12 Nm
Toothed belt guard	8 Nm