Coolant Pump, Removing and Installing

Coolant pump, removing and installing





Special tools and equipment
^ VAG1306 Drip tray for VAG1202A
^ VAG1331 Torque wrench: 5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG1921 Hose clip pliers
^ Anti-freeze tester

Removing

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

- Drain coolant
- Remove ribbed belt
- Disconnect fuel supply and return lines at fuel filter.
- Remove connector hose between charge air cooler and intake manifold
- Remove fuel filter with bracket
- Remove belt guard upper and middle sections
- Remove V-belt from camshaft sprocket, injection pump sprocket and coolant pump sprocket





- Unscrew mounting bolt -1- from pulley -2- and press downward approximately 30 mm.
- Unscrew mounting bolts -3- from coolant pump and carefully remove coolant pump -4- between engine bracket and toothed belt guard.

Installing
Installation is carried out in the reverse order of the removal procedure.

Note the following during installation:
- Moisten new O-ring -3- with clean engine coolant.
- Insert coolant pump -4- into engine block and tighten mounting bolts -5- to 15 Nm (11 ft. lbs.).

Note: Coolant pump plug points downward.

- Install pulley -2- and tighten mounting bolt -1- (replace). Tightening torque: 40 Nm (30 ft. lbs.) plus additional 90° (1/4 turn).
- Install and tighten toothed belt.
- Install fuel filter with bracket.
- Disconnect fuel supply and return lines at fuel filter.
- Install ribbed belt.
- Install connecting hose between charge air cooler and intake hose.
- Fill engine with coolant. Cooling System, Draining and Filling