Water Pump: Service and Repair

Coolant Pump

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Engine Support Adapter (10-222 A/3)

• Engine Support Feet (10-222 A/8)

• Shackle (10-222 A/12)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)


When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• Make sure there is enough clearance to moving or hot components to prevent damage to the lines.

Removing

- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover With Air Filter.

- Remove the battery.

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






- Remove the bolts - arrows - and remove the battery tray.


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 coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.

- Remove the connecting pipe - 4 -. To do so, disconnect the Secondary Air Injection (AIR) connecting pipe - 1 -, if equipped and the vent tube - 2 - and reposition the spring clamp - 3 -.






- Remove the right front wheel housing liner.

- Remove the generator, power steering pump and coolant pump ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Remove the 4 exhaust pipe with catalytic converter to exhaust manifold nuts - 2 - and the suspended mount bolts - 3 -.






- Remove the exhaust pipe with catalytic converter - 1 - from the manifold and tie up firmly to the side. Refer to => [ Exhaust Pipe with Catalytic Converter ] Exhaust Pipe With Catalytic Converter.

• The coupling element in the exhaust pipe with catalytic converter must not be bent more than 10°, otherwise it may be damaged.

- Remove the pendulum support.

with a Manual Transmission

- Remove the shift mechanism from the transmission.

with a Automatic Transmission

- Remove the selector lever cable from the transmission.

Installing the Engine Support Bridge (10-222 A) , Rabbit, from MY 2006 through 2009

- Position the engine support bridge (10-222 A) with the engine support feet (10-222 A/8). Support the engine and transmission assembly in the installed position using the engine support adapter (10-222A/3) and the shackle (10-222 A/12).






• The illustration shows the arrangement with a automatic transmission.

• In vehicles with a manual transmission, the spindle - A - is to be located toward the rear and secured to the reinforcement brace of the transmission.

Installing the Engine Support Bridge (10-222 A) , Golf, from MY 2010






- Position the engine support bridge (10-222 A) with the engine support feet (10-222 A/8). Support the engine and transmission assembly in the installed position as illustrated.

Note the following:

• The panel - A - must not be bent.

• Secure the shackle (10 - 222 A/12) on the reinforcing brace in vehicles with a manual transmissions and at the transport eye in vehicles with a automatic transmissions.

Continuation for All

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






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

- Remove the bolts - 5 - and place the coolant expansion tank on top of the engine with the hoses connected.

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






• Remove the single, lower rear bolt - 2 - through a hole in the wheel housing.

- Remove the transmission mount to transmission mount bracket bolts - arrows -.






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

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






Installing

Install in reverse order of removal. Note the following:

• Note the installed position of the coolant pump. The sealing plug in the housing points downward.

• Fill the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.

• Install the battery.

Tightening Specifications