VW Passat & Audi A4 1990-2000

Water Pump

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REMOVAL & INSTALLATION

CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


NOTE
Apply an anti-seizing compound to the water pump housing fastener threads before reinstalling them.

1990-97 Passat Models
2.0L Engines


Click image to see an enlarged view

Fig. The water pump and thermostat both mount into the same housing which is mounted onto the engine block-2.0L engines

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Set the heater control to the hot position.
  4.  
  5. Place a drain pan under the water pump.
  6.  
  7. Make sure the coolant temperature is less than 100°F (38°C)
  8.  
  9. Remove the attaching clip from the connector pipe that is going into the water pump.
  10.  
  11. Pull the connecting pipe from the water pump and allow the coolant to drain into the drain pan below.
  12.  
  13. If necessary, remove the expansion tank.
  14.  
  15. Remove the thermostat housing and thermostat from under the water pump housing, inspect the thermostat and replace as necessary or reinstall using a new seal.
  16.  
  17. Raise and safely support the vehicle. Loosen but don't remove the bolts holding the pulley to the water pump.
  18.  
  19. If necessary, remove the timing belt cover.
  20.  
  21. Remove the water pump drive belt, and then remove the water pump pulley. If access to the bolts for the water pump housing is blocked by the crankshaft pulley remove the pulley-to-timing belt sprocket mounting bolts, then remove the pulley.
  22.  
  23. Remove the water pump housing bolts and remove the water pump from its housing.
  24.  

To install:

  1. Be sure to clean the housing before installing the new gasket. Install the pump into the housing and torque the pump-to-housing bolts to 7 ft. lbs. (10 Nm).
  2.  
  3. Install the water pump drive pulley and torque the bolts to 15 ft. lbs. (20 Nm). If the crankshaft drive pulley was removed, install it and torque the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Adjust drive belt tension as necessary and if removed, install the thermostat and housing. Torque the housing bolts to 7 ft. lbs. (10 Nm).
  6.  
  7. Installation is in reverse order of removal noting the following:
  8.  
  9. Connect the negative battery cable and if necessary, enter the radio security code.
  10.  
  11. Fill, bleed and top off the cooling system using the recommended fluid type and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  12.  

2.8L VR6 Engines

NOTE
To Removal of the water pump on VR6 engines requires disconnecting the engine mounts and lifting the engine with the use of special engine lifting equipment to access the water pump.

  1. Remove the negative battery cable.
  2.  


NOTE
Always have the vehicle's antitheft code on hand before disconnecting the battery cable.

  1. Drain the cooling system.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the Intake Air Temperature (IAT) sensor from the intake manifold.
  6.  
  7. Loosen the coolant pump bolts once the accessory drive belt is loosened, but still installed.
  8.  


NOTE
It may be necessary to apply some pressure to the drive belt to keep the pulley from spinning.

  1. Remove the drive belt from the pulleys once the rotation direction of the belt has been marked.
  2.  
  3. Separate the exhaust pipe from the catalytic converter.
  4.  
  5. Unbolt and relocate the coolant reservoir out of your way.
  6.  
  7. Raise the engine slightly.
  8.  
  9. Remove the bolts from both the right and left rear engine mounts.
  10.  
  11. Remove the coolant pump mounting bolts.
  12.  
  13. Raise the engine just enough that the water pump can be removed.
  14.  

To install:

  1. Clean all surfaces of the pump and the mounting area before installing the pump.
  2.  
  3. Align the engine on its mounts using the engine alignment procedure.
  4.  
  5. Installation is in reverse order of removal noting the following:
  6.  
  7. Connect the negative battery cable and if necessary, enter the radio security code.
  8.  
  9. Fill, bleed and top off the cooling system using the recommended fluid type and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  10.  

A4 & 1998-00 Passat Models
1.8L Engine

The coolant pump is bolted to the brackets for the alternator, power steering pump, and cooling fan. To gain access to the front of the engine, the front bumper must be removed and the hood lock carrier assembly moved forward to the service position.

  1. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the lower engine slash shield.
  6.  
  7. Drain the engine coolant into a sealable container.
  8.  
  9. Remove the accessory drive belt, then the engine driven cooling fan.
  10.  
  11. Loosen the clamps for the coolant hoses at the water pump.
  12.  
  13. Remove the intake air duct between the intake manifold and the charge air (inter) cooler.
  14.  
  15. Remove the alternator mounting bolts and slide it forward.
  16.  
  17. Disconnect the wiring from the alternator once it is removed.
  18.  
  19. Unbolt the following supports and brackets for the alternator, power steering pump, and engine cooling fan:
  20.  
  21. Intake manifold support
  22.  
  23. Support for the engine torque bracket
  24.  
  25. Brace to the cylinder block (remove completely)
  26.  
  27. Remove the brackets for the alternator, power steering pump, and engine cooling fan.
  28.  
  29. Position the brackets for the alternator, power steering pump, and engine cooling fan to the left side using a piece of wire.
  30.  
  31. Pull off the coolant hoses from the pump and thermostat housing.
  32.  
  33. Unbolt the coolant pump housing from the timing belt cover.
  34.  
  35. Remove the coolant pump mounting bolts, then the pump.
  36.  
  37. Unbolt the impeller housing from the pump housing.
  38.  
  39. Clean all gasket and O-ring sealing surfaces.
  40.  



Click image to see an enlarged view

Fig. The water pump, alternator and power steering pump all mount to the same engine bracket-1.8L engines



Click image to see an enlarged view

Fig. Exploded view of the water pump, housing and related components-1.8L engine

To install:

  1. Using a new gasket, mount the new coolant pump to the pump housing and tighten the mounting bolts to 84 inch lbs. (10 Nm).
  2.  
  3. Using a new gasket and O-ring, install the coolant pump and tighten the mounting bolts in numerical sequence to 18 ft. lbs. (25 Nm).
  4.  
  5. Tighten the coolant pump housing to the timing belt cover to 84 inch lbs. (10 Nm).
  6.  
  7. Install the coolant hoses to the pump and thermostat housing.
  8.  
  9. Install the brackets that were removed and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Connect the wires to the alternator, then install the alternator.
  12.  
  13. Install the air intake duct between the intake manifold and the charge air cooler.
  14.  
  15. Installation is in reverse order of removal noting the following:
  16.  
  17. Verify that the key is in the OFF position before connecting the battery
  18.  
  19. Connect the negative battery cable and if necessary, enter the radio security code.
  20.  
  21. Fill, bleed and top off the cooling system using the recommended fluid type and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  22.  
  23. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the 1-touch opening/closing function
  24.  
  25. Set the clock to the correct time
  26.  
  27. After repositioning the (hood) lock carrier, check the wiring for proper routing near the cooling fan
  28.  

2.8L V6 Engine

On all A4 & 1998-00 Passat models, to gain access to the front of the engine, the front bumper must be removed and the (hood) lock carrier assembly moved forward to the service position.

  1. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the lower engine slash shield.
  6.  
  7. Drain the engine coolant into a sealable container.
  8.  
  9. Remove the accessory drive belt, then if equipped, the engine driven cooling fan.
  10.  
  11. Remove the drive belt, and then remove the timing belt covers.
  12.  
  13. remove the timing belt.
  14.  
  15. Remove the water pump mounting bolts, then the pump.
  16.  



Click image to see an enlarged view

Fig. Exploded view of the water pump and related components-2.8L V6 Engine



Click image to see an enlarged view

Fig. Once the camshaft drive belt has been removed the tensioner and idler rollers and related component are removed to access the water pump

Once the belt guard and water pump fasteners are removed, the pump is taken off

To install:


NOTE
Always replace the old gasket(s) and/or O-ring(s).

  1. Installation is the reverse of the removal procedure. Tighten the water pump retaining bolts to 84 inch lbs. (10 Nm) for the 2.8L V6 Engines.
  2.  
  3. Reinstall the timing belt and properly tension the belt with the water pump. Refer to the necessary service procedures.
  4.  
  5. Refill and bleed the cooling system.
  6.  
  7. Enter the radio security code.
  8.  

 
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