Volkswagen Golf Service & Repair Manual: Removing and installing coolant pump
| Special tools and workshop equipment required |
| Drip tray for workshop hoist -VAS 6208- |
| Hose clip pliers -VAS 6340- |
| Cooling system charge unit -VAS 6096- |
| Adapter for cooling system tester -V.A.G 1274/8- |
| Torque wrench -V.A.G 1410- |
| – |
Drain coolant
→ Chapter. |
| – |
Remove battery tray
→ Electrical system; Rep. gr.27. |
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| – |
Loosen hose clips -1, 2- and
remove air pipe. |
| – |
Move air hoses clear at air pipe. |
| – |
Detach connector from charge pressure sender -GX26-. |
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| – |
Release fasteners -arrows-
using release tools -T10527- and -T10527/1-. |
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| – |
Press release tabs and disconnect hose
-1- for activated charcoal filter. |
| – |
Remove bolts -arrows- and
detach crankcase breather hose. |
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| – |
Lay wiring harness to one side
-arrows-. |
| – |
Unscrew bolts -1, 3- and remove
cover -2- for toothed belt for
coolant pump. |
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| – |
Move clear electrical wiring harness
-1- and coolant hose -2-. |
| – |
Release hose clips -arrows-,
and disconnect all coolant hoses from coolant pump. |
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| – |
Loosen and unscrew bolts in the sequence
-5 … 1-. |
| – |
Detach coolant pump with toothed belt. |
| – |
Remove thermostat housing if coolant pump is being renewed
→ Chapter. |
 Note
| Renew gasket for housing -arrows-. |
| Renew the toothed belt of the coolant pump. |
| Secure hose connections with hose clips meeting production
standard
→ Electronic Parts Catalogue. |
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| – |
Ensure proper seating of gaskets
-arrows-. |
| – |
Lubricate seal for coolant pump lightly with coolant. |
Note
| 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 must be carried out with the aid of
a 2nd mechanic. |
| – |
Set No. 1 cylinder to TDC
→ Chapter. |
| – |
Fit toothed belt so that it is centred and move coolant pump
into installation position. |
| – |
Mount coolant pump on cylinder head with securing bolts. |
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| – |
Pre-tighten bolts in the specified sequence: |
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| Stage |
Bolts |
Specified torque |
| 1 |
-1 … 5- |
Screw in to contact by hand |
| 2 |
-1 … 5- |
10 Nm |
| – |
Loosen all bolts again by one turn. |
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| Stage |
Bolts |
Specified torque |
| 3 |
-2, 1, 5- |
10 Nm |
| 4 |
-3, 4, 5, 1, 2- |
12 Nm |
| Further installation steps are carried out in the reverse
order; note the following: |
| Coolant hose schematic diagram
→ Chapter. |
| – |
Replenish coolant
→ Anchor. |
| Tightening sequence for coolant pump
→ Anchor |
| → Chapter „Assembly overview - coolant pump, thermostat“ |
| → Chapter „Assembly overview - turbocharger“ |
| → Chapter „Assembly overview - charge air system“ |
| → Electrical system; Rep. gr.27 |
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1 -
O-ring
Renew
2 -
Radiator outlet coolant temperature sender -G83-
Removing and installing
→ C ...
Special tools and workshop equipment
required
Counterhold -T10172- with adapter -T10172/2-
...
Other materials:
Removing tyre sealant
Place wheel on an even surface.
–
Unscrew valve insert.
Caution
The tyre sealant is hazardous to the health.
May cause eye and skin irrit ...
Removing and installing digital sound package control unit -J525
Special tools and workshop equipment
required
Protective cap for wiring harness connector -VAS 6223/9-
If the control unit is replaced, select the
Replace function of the resp ...
Assembly overview - clutch engagement
1 -
Shim for “K 1”
Determining thickness
→ Chapter.
2 -
Large engaging lever for “K 1”
With engagement bearing
Removing and installing
→ Chapter
...
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Assembly overview - coolant temperature sender
Removing and installing toothed belt pulley for coolant pump, engine codes
CHPA, CMBA, CPVA, CXSA, CZDA, CZCA, CPVB