Volkswagen Cars 2000-05

Removal & Installation

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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.

1.8L Engine




NOTE
The coolant pump is bolted to the brackets for the generator, power steering pump, and cooling fan.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Position the lock carrier into the service position as follows:
    1. Remove or disconnect:
    2.  



    Front bumper.
     
    Any wiring or connector that would inhibit locking the carrier.
     
    3 quick-release screws on the front noise insulation panel.
     
    Air guide between the lock carrier and the air filter.
     
    Retaining clamps for the wiring harness at the left side of the radiator frame.
     
    No. 2 bolts and install Support tool 3369 or equivalent.
     
    Remaining bolts and pull the lock carrier out to the stop.
     
    To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
     

  4.  
  5. Remove or disconnect
    1. Negative battery cable.
    2.  
    3. Accessory drive belt, then the engine driven cooling fan.
    4.  
    5. Coolant.
    6.  
    7. Clamps for the coolant hoses at the water pump.
    8.  
    9. Intake air duct between the intake manifold and the charge air cooler.
    10.  
    11. Generator mounting bolts and slide it forward.
    12.  
    13. Wiring from the generator once it is removed.
    14.  

  6.  
  7. Unbolt the following supports and brackets for the generator, power steering pump, and engine cooling fan:

    Intake manifold support
     
    Support for the engine torque bracket
     
    Brace to the cylinder block (remove completely)
     

  8.  
  9. Remove or disconnect:
    1. Brackets for the generator, power steering pump, and engine cooling fan, positioning the brackets to the left side using a piece of wire
    2.  
    3. Coolant hoses from the pump and thermostat housing
    4.  
    5. Coolant pump housing from the timing belt cover
    6.  
    7. Coolant pump mounting bolts, then the pump
    8.  
    9. Impeller housing from the pump housing
    10.  

  10.  

To install:



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. Assembly bracket with water pump mounting bolt tightening sequence-1.8L engine



Using a new gasket, mount the new coolant pump to the pump housing. Mounting bolts: 84 inch lbs. (10 Nm).
 
Using a new gasket and O-ring, install the coolant pump. Mounting bolts in alphabetical sequence: 18 ft. lbs. (25 Nm).
 
Tighten the coolant pump housing to the timing belt cover to 84 inch lbs. (10 Nm).
 
Install or connect:
  1. Coolant hoses to the pump and thermostat housing.
  2.  
  3. Brackets that were removed. Mounting bolts: 18 ft. lbs. (25 Nm).
  4.  
  5. Wires to the generator, then install the generator.
  6.  
  7. Air intake duct between the intake manifold and the charge air cooler.
  8.  

 
The remaining steps are the reverse of the removal.
 
Fill the engine with coolant
 
Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
 
After installing the lock carrier, check the wiring for proper routing near the cooling fan
 

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.  


    Intake manifold support
     
    Support for the engine torque bracket
     
    Brace to the cylinder block (remove completely)
     

  21. Remove the brackets for the alternator, power steering pump, and engine cooling fan.
  22.  
  23. Position the brackets for the alternator, power steering pump, and engine cooling fan to the left side using a piece of wire.
  24.  
  25. Pull off the coolant hoses from the pump and thermostat housing.
  26.  
  27. Unbolt the coolant pump housing from the timing belt cover.
  28.  
  29. Remove the coolant pump mounting bolts, then the pump.
  30.  
  31. Unbolt the impeller housing from the pump housing.
  32.  
  33. Clean all gasket and O-ring sealing surfaces.
  34.  



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.  


NOTE
The coolant pump is bolted to the brackets for the generator, power steering pump, and cooling fan.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Position the lock carrier into the service position as follows:
    1. Remove or disconnect:

      Front bumper.
       
      Any wiring or connector that would inhibit locking the carrier.
       
      3 quick-release screws on the front noise insulation panel.
       
      Air guide between the lock carrier and the air filter.
       
      Retaining clamps for the wiring harness at the left side of the radiator frame.
       
      No. 2 bolts and install Support tool 3369 or equivalent.
       
      Remaining bolts and pull the lock carrier out to the stop.
       

    2.  
    3. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    4.  

  4.  
  5. Remove or disconnect

    Negative battery cable.
     
    Accessory drive belt, then the engine driven cooling fan.
     
    Coolant.
     
    Clamps for the coolant hoses at the water pump.
     
    Intake air duct between the intake manifold and the charge air cooler.
     
    Generator mounting bolts and slide it forward.
     
    Wiring from the generator once it is removed.
     

  6.  
  7. Unbolt the following supports and brackets for the generator, power steering pump, and engine cooling fan:
    1. Intake manifold support
    2.  
    3. Support for the engine torque bracket
    4.  
    5. Brace to the cylinder block (remove completely)
    6.  

  8.  
  9. Remove or disconnect:

    Brackets for the generator, power steering pump, and engine cooling fan, positioning the brackets to the left side using a piece of wire
     
    Coolant hoses from the pump and thermostat housing
     
    Coolant pump housing from the timing belt cover
     
    Coolant pump mounting bolts, then the pump
     
    Impeller housing from the pump housing
     

  10.  

To install:

Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. Assembly bracket with water pump mounting bolt tightening sequence-1.8L engine

  1. Using a new gasket, mount the new coolant pump to the pump housing. Mounting bolts: 84 inch lbs. (10 Nm).
  2.  
  3. Using a new gasket and O-ring, install the coolant pump. Mounting bolts in alphabetical sequence: 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 or connect:

    Coolant hoses to the pump and thermostat housing.
     
    Brackets that were removed. Mounting bolts: 18 ft. lbs. (25 Nm).
     
    Wires to the generator, then install the generator.
     
    Air intake duct between the intake manifold and the charge air cooler.
     

  8.  
  9. The remaining steps are the reverse of the removal.
  10.  
  11. Fill the engine with coolant
  12.  
  13. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  14.  
  15. After installing the lock carrier, check the wiring for proper routing near the cooling fan
  16.  

1.9L (Aaz) Engine



On some Diesel engines, the belt tension is adjusted with shims between the outer and inner halves of the pulley. On others, the alternator swivels to adjust belt tension.

  1. To drain the cooling system, remove the thermostat housing from under the water pump housing.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Working under the vehicle, loosen but don't remove the bolts holding the pulley to the water pump.
  6.  
  7. On vehicles with a movable alternator, loosen the alternator and remove the drive belt.
  8.  
  9. Remove the water pump pulley and remove the pump.
  10.  

To install:

  1. Installation is the reverse of removal. Be sure to clean the pump housing before installing the new gasket. Tighten the following:

    Water pump-to-housing-7 ft. lbs. (10 Nm)
     
    Water pump drive pulley-15 ft. lbs. (20 Nm)
     
    Thermostat housing-7 ft. lbs. (10 Nm)
     
    Alternator mounting bolts-18 ft. lbs. (25 Nm)
     

  2.  



Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.9L (AAZ) engine

On some Diesel engines, the belt tension is adjusted with shims between the outer and inner halves of the pulley. On others, the alternator swivels to adjust belt tension.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the coolant.
  4.  
  5. Loosen but don't remove the bolts holding the pulley to the water pump.
  6.  
  7. With a movable alternator, loosen the alternator and remove the drive belt.
  8.  
  9. Remove the water pump pulley and water pump.
  10.  

To install:

  1. Installation is the reverse of removal. Be sure to clean the pump housing before installing the new gasket. Tighten the following:

    Water pump-to-housing-84 inch lbs. (10 Nm)
     
    Water pump drive pulley-15 ft. lbs. (20 Nm)
     
    Thermostat housing-84 inch lbs. (10 Nm)
     
    Alternator mounting bolts-18 ft. lbs. (25 Nm)
     

  2.  


    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-1.9L (AAZ) engine


1.9L (Ahh) Engine





Click image to see an enlarged view

Fig. Exploded view of the coolant pump, bracket and related components-1.9L (AHH) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover and under cover.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Position the lock carrier into the service position, as follows:
    1. Remove the front bumper.
    2.  
    3. Tag and remove any wiring or connector that would inhibit locking the carrier.
    4.  
    5. Remove the three quick-release screws on the front noise insulation panel.
    6.  
    7. Unbolt the air guide between the lock carrier and the air filter.
    8.  
    9. If installed, remove the retaining clamps for the wiring harness at the left side of the radiator frame.
    10.  
    11. Remove the No. 2 bolts and install Support tool 3369 or equivalent.
    12.  
    13. Remove the remaining bolts and pull the lock carrier out to the stop.
    14.  
    15. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    16.  

  8.  
  9. Remove the accessory drive belt, fan clutch and belt pulleys.
  10.  
  11. If necessary, remove the drive belt tensioner.
  12.  
  13. Remove the coolant pump assembly bracket.
  14.  
  15. Remove the coolant pump from the bracket.
  16.  
  17. Clean all gasket and sealing surfaces.
  18.  

To install:

  1. Using a new O-ring, install the coolant pump onto the bracket and tighten the mounting bolts to 7 ft. lbs. (10 Nm).
  2.  
  3. Using a new gasket and O-ring, install the coolant pump bracket and tighten the mounting bolts in alphabetical sequence to 18 ft. lbs. (25 Nm).
  4.  



Click image to see an enlarged view

Fig. Coolant pump bracket torque sequence-1.9L (AHH) engine

  1. Tighten the coolant pump housing to the timing belt cover mounting bolt (F) to 7 ft. lbs. (10 Nm).
  2.  
  3. If removed, install the drive belt tensioner.
  4.  
  5. Install the belt pulleys, fan clutch and accessory drive belt.
  6.  
  7. Return the lock carrier into the normal position.
  8.  
  9. Fill the engine with coolant.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the vehicle and check for leaks.
  14.  
  15. Install the engine cover and under cover.
  16.  
  17. Check and clear any Diagnostic Trouble Codes (DTCs).
  18.  



Click image to see an enlarged view

Fig. Exploded view of the coolant pump, bracket and related components-1.9L (AHH) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Engine cover and under cover
     
    Coolant
     

  4.  
  5. Position the lock carrier into the service position, as follows:
    1. Remove or disconnect:
    2.  



    Front bumper
     
    Any wiring or connector that would inhibit locking the carrier
     
    3 quick-release screws on the front noise insulation panel
     
    Air guide between the lock carrier and the air filter
     
    If installed, retaining clamps for the wiring harness at the left side of the radiator frame
     
    No. 2 bolts and install Support tool 3369 or equivalent
     
    Remaining bolts and pull the lock carrier out to the stop
     
    To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender
     

  6.  
  7. Remove or disconnect:
    1. Accessory drive belt, fan clutch and belt pulleys
    2.  
    3. If necessary, drive belt tensioner
    4.  
    5. Coolant pump assembly bracket
    6.  
    7. Coolant pump from the bracket
    8.  

  8.  

To install:



Using a new O-ring, install the coolant pump onto the bracket and tighten the mounting bolts to 84 inch lbs. (10 Nm).
 
Using a new gasket and O-ring, install the coolant pump bracket. Mounting bolts, in alphabetical sequence: 18 ft. lbs. (25 Nm).
 
Tighten the coolant pump housing to the timing belt cover mounting bolt (F) to 84 inch lbs. (10 Nm).
 
If removed, install the drive belt tensioner.
 
Install the belt pulleys, fan clutch and accessory drive belt.
 
Return the lock carrier into the normal position.
 
Install or connect:
  1. Coolant
  2.  
  3. Negative battery cable
  4.  
  5. Engine cover and under cover
  6.  

 


Click image to see an enlarged view

Fig. Coolant pump bracket torque sequence-1.9L (AHH) engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Engine cover and under cover
     
    Coolant
     

  4.  
  5. Position the lock carrier into the service position, as follows:
    1. Remove or disconnect:

      Front bumper
       
      Any wiring or connector that would inhibit locking the carrier
       
      3 quick-release screws on the front noise insulation panel
       
      Air guide between the lock carrier and the air filter
       
      If installed, retaining clamps for the wiring harness at the left side of the radiator frame
       
      No. 2 bolts and install Support tool 3369 or equivalent
       
      Remaining bolts and pull the lock carrier out to the stop
       

    2.  
    3. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender
    4.  

  6.  
  7. Remove or disconnect:

    Accessory drive belt, fan clutch and belt pulleys
     
    If necessary, drive belt tensioner
     
    Coolant pump assembly bracket
     
    Coolant pump from the bracket

    Click image to see an enlarged view

    Fig. Exploded view of the coolant pump, bracket and related components-1.9L (AHH) engine

     

  8.  

To install:

  1. Using a new O-ring, install the coolant pump onto the bracket and tighten the mounting bolts to 84 inch lbs. (10 Nm).
  2.  
  3. Using a new gasket and O-ring, install the coolant pump bracket. Mounting bolts, in alphabetical sequence: 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Coolant pump bracket torque sequence-1.9L (AHH) engine

  4.  
  5. Tighten the coolant pump housing to the timing belt cover mounting bolt (F) to 84 inch lbs. (10 Nm).
  6.  
  7. If removed, install the drive belt tensioner.
  8.  
  9. Install the belt pulleys, fan clutch and accessory drive belt.
  10.  
  11. Return the lock carrier into the normal position.
  12.  
  13. Install or connect:

    Coolant
     
    Negative battery cable
     
    Engine cover and under cover
     

  14.  

1.9L (Alh) Engine





Before servicing the vehicle, refer to the Precautions section.
 
Remove or disconnect:
  1. Negative battery cable
  2.  
  3. Engine cover and under cover
  4.  
  5. Coolant
  6.  
  7. Accessory drive belt
  8.  
  9. Fuel supply and return lines at the filter
  10.  
  11. Hose between the charge air cooler and the intake manifold
  12.  
  13. Fuel filter and bracket
  14.  
  15. Timing belt upper and center covers
  16.  
  17. Timing belt tension, then remove the belt from the camshaft sprocket, injection pump sprocket and coolant pump sprocket
  18.  
  19. Coolant pump mounting bolts, then the pump
  20.  
  21. O-ring and clean the seating area
  22.  

 

To install:



Click image to see an enlarged view

Fig. Exploded view of the water pump mounting-1.9L (ALH) engine



Moisten a new O-ring with coolant, then install.
 
Install or connect:
  1. Water pump, so that the plug in the housing faces downward. Mounting bolts: 11 ft. lbs. (15 Nm).
  2.  
  3. Timing belt.
  4.  
  5. Upper and center timing belt covers.
  6.  
  7. Fuel filter and bracket.
  8.  
  9. Fuel lines.
  10.  
  11. Hose between the charge air cooler and the intake manifold.
  12.  
  13. Accessory drive belt tensioner and tighten the new bolt to 30 ft. lbs. (40 Nm), plus an additional 90°.
  14.  
  15. Accessory drive belt.
  16.  
  17. Coolant.
  18.  
  19. Negative battery cable.
  20.  

 

1.9L (Alh/Bew/Brm) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable
     
    Engine cover and under cover
     
    Coolant
     
    Accessory drive belt
     
    Fuel supply and return lines at the filter
     
    Hose between the charge air cooler and the intake manifold
     
    Fuel filter and bracket
     
    Timing belt upper and center covers
     
    Timing belt tension, then remove the belt from the camshaft sprocket, injection pump sprocket and coolant pump sprocket
     
    Coolant pump mounting bolts, then the pump
     
    O-ring and clean the seating area
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the water pump mounting-1.9L (ALH) engine

  1. Moisten a new O-ring with coolant, then install.
  2.  
  3. Install or connect:

    Water pump, so that the plug in the housing faces downward. Mounting bolts: 11 ft. lbs. (15 Nm).
     
    Timing belt.
     
    Upper and center timing belt covers.
     
    Fuel filter and bracket.
     
    Fuel lines.
     
    Hose between the charge air cooler and the intake manifold.
     
    Accessory drive belt tensioner and tighten the new bolt to 30 ft. lbs. (40 Nm), plus an additional 90°.
     
    Accessory drive belt.
     
    Coolant.
     
    Negative battery cable.
     

  4.  

2.0L (Aba) Engine





Before servicing the vehicle, refer to the Precautions section.
 
Remove or disconnect:
  1. Coolant
  2.  
  3. Thermostat housing from under the water pump housing.
  4.  

 
Loosen but don't remove the bolts holding the pulley to the water pump.
 
Remove or disconnect:

Timing belt cover.
 
Alternator and/or steering pump as required to remove the water pump drive belt.
 
Water pump pulley. On some vehicles, the crankshaft pulley must also be removed by removing the bolts holding the pulley to the timing belt sprocket.
 
Water pump from its housing.
 

 

To install:



Be sure to clean the housing before installing the new gasket. Install the pump into the housing. Pump-to-housing bolts: 84 inch lbs. (10 Nm).
 
Install the water pump drive pulley. Bolts: 15 ft. lbs. (20 Nm). Install crankshaft drive pulley. Bolts: 15 ft. lbs. (20 Nm).
 
Adjust drive belt tension and install the thermostat and housing. Bolts: 84 inch lbs. (10 Nm).
 


Click image to see an enlarged view

Fig. Water pump and thermostat housing-2.0L (ABA) engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Coolant
     
    Thermostat housing from under the water pump housing.
     

  4.  
  5. Loosen but don't remove the bolts holding the pulley to the water pump.
  6.  
  7. Remove or disconnect:

    Timing belt cover.
     
    Alternator and/or steering pump as required to remove the water pump drive belt.
     
    Water pump pulley. On some vehicles, the crankshaft pulley must also be removed by removing the bolts holding the pulley to the timing belt sprocket.
     
    Water pump from its housing.

    Click image to see an enlarged view

    Fig. Water pump and thermostat housing-2.0L (ABA) engine

     

  8.  

To install:

  1. Be sure to clean the housing before installing the new gasket. Install the pump into the housing. Pump-to-housing bolts: 84 inch lbs. (10 Nm).
  2.  
  3. Install the water pump drive pulley. Bolts: 15 ft. lbs. (20 Nm). Install crankshaft drive pulley. Bolts: 15 ft. lbs. (20 Nm).
  4.  
  5. Adjust drive belt tension and install the thermostat and housing. Bolts: 84 inch lbs. (10 Nm).
  6.  

2.0L (Aeg/Avh/Azg/Bdc/Bev/Bgd) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Coolant.
     
    Accessory drive belt and tensioner.
     
    Upper and center timing belt covers.
     

  4.  
  5. Position the engine so that the No. 1 cylinder is at TDC.
    WARNING
    Cover the timing belt to protect it from being contaminated with coolant.

  6.  
  7. Loosen the timing belt tension and slide the belt off the water pump sprocket.
  8.  
  9. Remove or disconnect:

    Timing belt guard (2) mounting bolt (1), if equipped.
     
    Water pump mounting bolts (5), then the water pump (4).
     
    O-ring (3) and clean the seating area.
     

  10.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the water pump mounting-2.0L (AEG/AVH/AZG/BDF) engine

  1. Install or connect:

    O-ring, moistened with coolant.
     
    Water pump so that the plug in the housing faces downward. Mounting bolts: 11 ft. lbs. (15 Nm).
     
    Timing belt guard, if equipped. Mounting bolt: 15 ft. lbs. (20 Nm).
     
    Timing belt.
     
    Upper and center timing belt covers.
     
    Accessory drive belt tensioner. Mounting bolt: 18 ft. lbs. (25 Nm).
     
    Accessory drive belt.
     
    Coolant.
     
    Negative battery cable.
     

  2.  
  3. Check and clear any DTCs, then match the ECM to the TCM.
  4.  

2.0L (Aeg/Avh/Azg/Bdf) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:
    1. Negative battery cable.
    2.  
    3. Coolant.
    4.  
    5. Accessory drive belt and tensioner.
    6.  
    7. Upper and center timing belt covers.
    8.  

  4.  
  5. Position the engine so that the No. 1 cylinder is at TDC.
  6.  


WARNING
Cover the timing belt to protect it from being contaminated with coolant.



Loosen the timing belt tension and slide the belt off the water pump sprocket.
 
Remove or disconnect:
  1. Timing belt guard (2) mounting bolt (1).
  2.  
  3. Water pump mounting bolts (5), then the water pump (4).
  4.  
  5. O-ring (3) and clean the seating area.
  6.  

 

To install:



Click image to see an enlarged view

Fig. Exploded view of the water pump mounting-2.0L (AEG/AVH/AZG/BDF) engine



Install or connect:
  1. O-ring, moistened with coolant.
  2.  
  3. Water pump so that the plug in the housing faces downward. Mounting bolts: 11 ft. lbs. (15 Nm).
  4.  
  5. Timing belt guard. Mounting bolt: 15 ft. lbs. (20 Nm).
  6.  
  7. Timing belt.
  8.  
  9. Upper and center timing belt covers.
  10.  
  11. Accessory drive belt tensioner. Mounting bolt: 18 ft. lbs. (25 Nm).
  12.  
  13. Accessory drive belt.
  14.  
  15. Coolant.
  16.  
  17. Negative battery cable.
  18.  

 
Check and clear any DTCs, then match the ECM to the TCM.
 

2.8L (Aaa) Engine





Before servicing the vehicle, refer to the Precautions section.
 
Remove or disconnect:
  1. Negative battery cable.
  2.  
  3. Front exhaust pipe from the catalytic converter.
  4.  
  5. Coolant.
  6.  
  7. Accessory drive belt.
  8.  
  9. Air intake duct.
  10.  
  11. Ignition wires from the coils and unclip them from the retainers.
  12.  
  13. Ignition wire guide above coil assembly.
  14.  
  15. Vacuum hose from the fuel pressure regulator.
  16.  
  17. IAT sensor from the upper intake manifold.
  18.  

 
Without disconnecting the hoses, remove and place the coolant expansion tank to the side.
 
Install an engine support fixture to the lifting eyes on the left and right sides of the cylinder head. Lift the engine slightly to remove the weight from the mounts.
 
Remove or disconnect:

Right and left rear engine/transaxle mount center bolts.
 
Front engine mounting center bolts.
 

 
Carefully raise the engine to gain access to the water pump pulley mounting bolts.
 
Remove the water pump pulley using wrench VAG 1590 or equivalent. Modify the wrench as shown if necessary to fit the bolt.
 
Remove the mounting bolts and the water pump.
 


Click image to see an enlarged view

Fig. Modify wrench VAG 1590 or equivalent to fit the water pump pulley bolt as needed


To install:



Install or connect:
  1. Water pump, using a new O-ring. Mounting bolts: 15 ft. lbs. (20 Nm).
  2.  
  3. Water pump pulley. Bolt: 18 ft. lbs. (25 Nm).
  4.  
  5. Engine/transaxle mount bolts. Mounting bolts: 44 ft. lbs. (60 Nm). Tighten the front and right rear mounts first, then the left rear mount.
  6.  
  7. Expansion tank. Bolts: 84 inch lbs. (10 Nm).
  8.  
  9. IAT sensor in the upper intake manifold.
  10.  
  11. Vacuum hose to the fuel pressure regulator.
  12.  
  13. Ignition wires and the wire guide.
  14.  
  15. Air duct and accessory drive belt.
  16.  
  17. Coolant.
  18.  

 

2.8L (Aha/Atq) Engine





Before servicing the vehicle, refer to the Precautions section.
 
Disconnect the negative battery cable.
 
Lock the carrier into service position as follows:
  1. Remove or disconnect:
  2.  

  1. Front bumper.
  2.  
  3. Any wiring or connector that would inhibit locking the carrier.
  4.  
  5. 3 quick-release screws on the front noise insulation panel.
  6.  
  7. Air guide between the lock carrier and the air filter.
  8.  
  9. Retaining clamps for the wiring harness at the left side of the radiator frame.
  10.  
  11. No. 2 bolts and install Support 3369 or equivalent.
  12.  
  13. Remaining bolts and pull the lock carrier out to the stop.
  14.  
  15. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
  16.  

 
Remove or disconnect:

Accessory drive belt.
 
Timing belt.
 
Coolant.
 
Timing belt tensioner and idler rollers.
 
Water pump mounting bolts, then the pump.
 

 

To install:

  1. Install or connect:

    New gasket on the water pump flange.
     
    Water pump. Mounting bolts: 10 ft. lbs. (15 Nm).
     
    Timing belt idler roller. Mounting bolt: 33 ft. lbs. (45 Nm).
     
    Timing belt tensioner roller. Mounting bolt: 15 ft. lbs. (20 Nm).
     
    Timing belt and accessory drive belt.
     
    Coolant.
     

  2.  
  3. Return the lock carrier to the normal position.
  4.  
  5. Connect the negative battery cable.
  6.  

2.8L (Atq) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Lock the carrier into service position as follows:
    1. Remove or disconnect:

      Front bumper.
       
      Any wiring or connector that would inhibit locking the carrier.
       
      3 quick-release screws on the front noise insulation panel.
       
      Air guide between the lock carrier and the air filter.
       
      Retaining clamps for the wiring harness at the left side of the radiator frame.
       
      No. 2 bolts and install Support 3369 or equivalent.
       
      Remaining bolts and pull the lock carrier out to the stop.
       

    2.  
    3. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    4.  

  6.  
  7. Remove or disconnect:

    Accessory drive belt.
     
    Timing belt.
     
    Coolant.
     
    Timing belt tensioner and idler rollers.
     
    Water pump mounting bolts, then the pump.
     

  8.  

To install:

  1. Install or connect:

    New gasket on the water pump flange.
     
    Water pump. Mounting bolts: 10 ft. lbs. (15 Nm).
     
    Timing belt idler roller. Mounting bolt: 33 ft. lbs. (45 Nm).
     
    Timing belt tensioner roller. Mounting bolt: 15 ft. lbs. (20 Nm).
     
    Timing belt and accessory drive belt.
     
    Coolant.
     

  2.  
  3. Return the lock carrier to the normal position.
  4.  
  5. Connect the negative battery cable.
  6.  

2.8L (Bdf) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Drain the coolant.
  8.  
  9. Using a socket through the holes in the pump pulley, remove the bolts and remove water pump.
  10.  

To install:



Install or connect:
  1. New O ring on the water pump.
  2.  
  3. Water pump. Mounting bolts: 15 ft. lbs. (20 Nm).
  4.  
  5. Accessory drive belt.
  6.  
  7. Coolant.
  8.  

 

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Drain the coolant.
  8.  
  9. Using a socket through the holes in the pump pulley, remove the bolts and remove water pump.
  10.  

To install:

  1. Install or connect:

    New O ring on the water pump.
     
    Water pump. Mounting bolts: 15 ft. lbs. (20 Nm).
     
    Accessory drive belt.
     
    Coolant.
     

  2.  

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



Click image to see an enlarged view

Fig. 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.  

4-Cylinder Gasoline Engines





Click image to see an enlarged view

Fig. Exploded view of a typical 4 cyl. VW water pump


NOTE
Complete failure of the water pump is not normally the case. Although after many miles coolant may begin to leak from the pump shaft. The pump must be replaced if it is leaking coolant.

  1. Remove the expansion tank cap.
  2.  


CAUTION
Do not remove the expansion tank cap if the engine is hot. Hot coolant can cause harm. Always allow the engine to cool before performing any work to the cooling system.

  1. Set the heater control to the hot position.
  2.  
  3. Place a drain pan under the water pump.
  4.  
  5. Remove the attaching clip from the connector pipe that is going into the water pump.
  6.  
  7. Pull the connecting pipe from the water pump and allow the coolant to drain into the drain pan below.
  8.  
  9. Remove the negative battery cable.
  10.  


NOTE
Always know the anti-theft code before disconnecting the negative battery cable.


    4.0L (Bdp) Engine



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the accessory drive belt.
    6.  
    7. Drain the coolant.
    8.  
    9. Remove the water pump bolts and the water pump.
    10.  

    To install:



    Install or connect:
    1. New O ring on the water pump.
    2.  
    3. Water pump. Mounting bolts: 15 ft. lbs. (20 Nm).
    4.  
    5. Accessory drive belt.
    6.  
    7. Coolant.
    8.  

     

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the accessory drive belt.
    6.  
    7. Drain the coolant.
    8.  
    9. Remove the water pump bolts and the water pump.
    10.  

    To install:

    1. Install or connect:

      New O ring on the water pump.
       
      Water pump. Mounting bolts: 15 ft. lbs. (20 Nm).
       
      Accessory drive belt.
       
      Coolant.
       

    2.  

    Vr6




    NOTE
    To remove the coolant pump on VR6 engines you will need special engine lifting equipment.

    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. Loosen the coolant pump bolts once the accessory drive belt is loosened but still installed.
    6.  


    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 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 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. The remainder of the procedure is the reverse of removal.
    6.  

     
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