Water Pump: Service and Repair

Coolant Pump Removing and Installing




Special tools, workshop equipment, test and measuring appliances and aux. items required
- T10007
- Refractometer
- V.A.G 1306
- Drip tray
- V.A.G 1331 Torque wrench (5 to 50 Nm)
- VAS 5024 Assembly tool for spring type clamps




Cooling System Components (Engine Side)
1 Bolt. Torque Specification: 15 Nm (11 ft. lbs.)
2 Toothed belt - Mark D.O.R. before removing
3 Coolant pump
4 O-ring - Replace
5 Coolant thermostat
6 O-ring - Replace
7 Connection To heat exchanger
9 O-ring - Replace
10 4 pin Connector
11 Coolant Temperature Sender For engine control module (G62) - With coolant temperature gauge sender (G2)
12 Retaining clip - Check seated securely
13 Upper coolant hose - Secured to radiator with retaining clip
14 Lower coolant hose - Secured to radiator with retaining clip
15 Oil cooler - From heat exchanger
17 Lower coolant pipe
18 Bolt. Torque Specification: 10 Nm (7 ft. lbs.)
19 Cap. Test pressure 1.4 to 1.6 bar (20 to 23 psi
20 Seal - Replace if damaged
21 Bolt. Torque Specification: 10 Nm (7 ft. lbs.)
22 Expansion tank
23 To turbocharger
24 Bolt. Torque Specification 15 Nm (11 ft. lbs.)
25 To upper coolant hose - Only on engine code AWP with automatic transmission.
26 After-run coolant pump (V51) - Only on engine code AWP with automatic transmission.
27 From-turbocharger - Only on engine code AWP with automatic transmission.

Notes:
Always replace seals and gaskets.
The lower part of the toothed belt guard need not be removed.
The toothed belt should be left position on the crankshaft sprocket.
Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.

Removing
- Drain coolant. Refer to: Cooling System, Service and Repair. Service and Repair
- Remove ribbed belt. Refer to: Drive Belts, Service and Repair. Drive Belts, Mounts, Brackets and Accessories
- Remove upper and center parts of toothed belt guard. Refer to: Procedures
- Take toothed belt off coolant pump toothed belt sprocket.




- Unscrew coolant pump securing bolts-1 and remove coolant pump-2-.

Installing
Installation is carried out in the reverse order, when doing this note the following:
- Moisten new O-ring with coolant.
- Insert coolant pump into cylinder block and tighten securing bolts. Torque Specification: 15 Nm (11 ft. Lbs.)

Note: The coolant pump plug faces downwards.

- Installing toothed belt and adjusting timing.
- Install ribbed belt.
- Fill with new coolant.