Water Pump: Service and Repair

Coolant pump, removing/installing

Removing

CAUTION:
- Wait at least 20 seconds after switching off ignition before disconnecting battery. This will allow the platinum hot-wire in Air Mass-Sensor (G70) to burn itself clean.
- Always switch off ignition when disconnecting/reconnecting battery, or any part of Motronic ignition wiring system to prevent damage to Motronic control unit (J 220).
- Always obtain security code before disconnecting battery ground strap.

- switch off ignition
- disconnect battery ground strap
- drain coolant, Service and Repair
- disconnect front exhaust pipe at flange to catalyst
- replace fastening nuts
- remove poly ribbed belt, Service and Repair




- disconnect engine with bracket from front engine rubber mount, from top (as shown)




- disconnect engine with bracket from rear engine rubber mount (as shown)




- unscrew transmission with bracket on rear transmission rubber mount (as shown)




- remove ignition cable guide




CAUTION! Use cotter pins on hooks and holding pins (arrows) to secure engine sling 2O24A.

- attach engine sling, as shown and take weight with crane

Pulley side (left arrow)
- fourth hole in vertical bar at position 1

Flywheel side (right arrow)
- fourth hole in vertical bar at position 8

The positions marked 1-4 on the bar must be towards the pulley side. The holes in the vertical bar are counted upwards from the hook.

- lift engine with transmission sufficiently to gain access to coolant pump
- using water pump wrench VAG 1590, remove coolant pump pulley
- unscrew coolant pump
- remove pump by pushing engine/transmission slightly by hand to the left for clearance


Installing

Reinstall all components in reverse order, noting the following:




- when installing engine brackets ensure that the recess on the right rear engine bracket and the front engine bracket fits into the mounting tab of the bonded rubber bushings (arrow)
- hand tighten engine and transmission carrier bolts approximately 5 - 6 turns
- lightly rock or shake engine to adjust position
- fully tighten engine, then transmission carrier bolts
- reinstall poly-ribbed belt, Service and Repair
- refill coolant, Service and Repair

Tightening torques
Pulley to pump 25 Nm (18 ft lb)
Coolant pump to cylinder block 20 Nm (15 ft lb)
Exhaust pipe to catalytic convertor 25 Nm (18 ft lb)

Engine/transmission carrier, brackets, Service and Repair