Volkswagen Golf Service & Repair Manual: Removing and installing coolant pump

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Engine cooling / Coolant pump, regulation of cooling system / Removing and installing coolant pump

Removing and installing coolant pump

Special tools and workshop equipment required

Refractometer -T10007 A-

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 -VAS 6583-

Torque wrench -V.A.G 1410-

Release tool -T10527-

Release tool -T10527/1-

Removing

–	Drain coolant → Chapter.

–	Remove battery tray → Electrical system; Rep. gr.27.

Removing and installing coolant pump

–	Loosen hose clips -1, 2- and remove air pipe.

–	Move air hoses clear at air pipe.

–	Detach connector from charge pressure sender -GX26-.

Removing and installing coolant pump

–	Release fasteners -arrows- using release tools -T10527- and -T10527/1-.

–	Remove air pipe -1-.

Removing and installing coolant pump

–	Press release tabs and disconnect hose -1- for activated charcoal filter.

–	Remove bolts -arrows- and detach crankcase breather hose.

Removing and installing coolant pump

–	Lay wiring harness to one side -arrows-.

–	Unscrew bolts -1, 3- and remove cover -2- for toothed belt for coolant pump.

Removing and installing coolant pump

–	Move clear electrical wiring harness -1- and coolant hose -2-.

–	Release hose clips -arrows-, and disconnect all coolant hoses from coolant pump.

Removing and installing coolant pump

–	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.

Installing

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.

Removing and installing coolant pump

–	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.

Removing and installing coolant pump

–	Pre-tighten bolts in the specified sequence:

Removing and installing coolant pump

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.

–	Apply torque wrench -VAS 6583- with hexagon key (10 mm) -item 6- to coolant pump.

Note

For ease of handling, apply torque wrench -VAS 6583- vertically.

–	Have a second mechanic apply a torque of 30 Nm to coolant pump.

Note

Do not support torque wrench with your other hand.

Do not apply »excessive force« to torque wrench.

–	While keeping coolant pump under tension, tighten bolts for coolant pump in specified sequence:

Removing and installing coolant pump

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.

Specified torques

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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