Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Water Pump

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

4-Cylinder Gasoline Engines

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable and drain the cooling system.
  2.  
  3. If required, remove the alternator and drive belt for additional access.
  4.  
  5. Remove the timing belt covers.
  6.  
  7. Remove the pump pulley. If the water pump is to be reused, matchmark it to the pump pulley first.
  8.  



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Fig. Fig. 1: If the water pump is to be reused, matchmark the pump pulley to allow installation in the same position

  1. Disconnect the lower radiator hose, engine hose, and heater hose from the water pump.
  2.  
  3. Remove the metal plate covering the water pump, then remove the pump-to-housing retaining bolts. Make a note of where the different length bolts are located.
  4.  



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Fig. Fig. 2: Remove the bolts securing the metal plate which covers the water pump



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Fig. Fig. 3: Access to the water pump bolts is much easier with the pump pulley removed

  1. Turn the pump slightly, then lift it out of the pump housing. If the pump is stubborn, tap around the edges of the pump with a rubber mallet to loosen it, then separate the pump from the pump housing. Clean the pump housing gasket surface to remove all traces of the gasket material.
  2.  



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Fig. Fig. 4: Turn the pump slightly, then lift it out of the pump housing



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Fig. Fig. 5: Always discard the old gasket

To install:
  1. Install a new O-ring seal into the pump. Make sure the seal seats evenly in the groove. Lubricate the seal with a liberal coat of silicone compound prior to installation.
  2.  
  3. Place the new pump gasket onto the pump housing, then install the pump. Install one of the mounting bolts to hold the pump and gasket in place. Make sure all the gasket bolt holes are aligned properly with the holes in the housing before installing the remaining bolts. Torque the bolts to 7 ft. lbs. (10 Nm). Torque the pulley bolts to 15 ft. lbs. (20 Nm), then adjust the belt tension.
  4.  

On 1985-89 Golf models, install the water pump pulley with the word "Klima" facing outward.

  1. Connect the radiator and heater hoses.
  2.  
  3. Install the timing belt cover.
  4.  
  5. If removed, install the alternator and adjust the drive belt tension.
  6.  
  7. Fill the cooling system. Start the engine and check for leaks.
  8.  

5-Cylinder Engines

Some replacement water pumps for five cylinder engines have a larger O-ring seal groove that does not accept the standard 4mm O-ring seal. Instead, an oversized 5mm seal must be used. Pumps that require a 5mm seal are stamped with a "5" on the water pump bolt flange area. Make sure that you use the proper O-ring seal when installing the water pump.

  1. Disconnect the negative battery cable and drain the cooling system.
  2.  
  3. Loosen the three water pump pulley retaining bolts.
  4.  
  5. Remove the V-belts, timing belt covers and timing belt as outlined in this section.
  6.  
  7. Unscrew the three water pump pulley retaining bolts, then remove the pulley.
  8.  
  9. Remove the intermediate shaft drive sprocket retaining bolt, then remove the sprocket.
  10.  
  11. Unscrew the water pump retaining bolts and remove the pump from its housing. If the pump is stubborn, tap around the edges of the pump with a rubber mallet to loosen it, then separate the pump from the pump housing. Clean the pump housing gasket surface to remove all traces of the gasket material. Remove the pump pulley and transfer it to the new pump.
  12.  

To install:
  1. Install a new O-ring seal into the pump. Make sure the seal seats evenly in the groove. Lubricate the seal with a liberal coat of silicone compound prior to installation.
  2.  
  3. Place the new pump gasket onto the pump housing and install the pump onto the gasket. Install one of the mounting bolts to hold the pump and gasket in place. Make sure all the gasket bolt holes are aligned properly with the holes in the housing before installing the remaining bolts. Torque the bolts to 15 ft. lbs. (20 Nm). Torque the pulley bolts to 15 ft. lbs. (20 Nm). It will be easier to torque the pulley bolts after the belt has been installed and tensioned.
  4.  
  5. Mount the intermediate drive shaft sprocket and install the retaining bolt.
  6.  
  7. Install the timing belt, timing belt covers and drive belts. Adjust the drive belt tension.
  8.  
  9. Refill the cooling system and connect the negative battery cable. Start the engine and check for leaks.
  10.  

Diesel Engine

Some replacement water pumps for Quantum turbo diesel engines have a larger O-ring seal groove that does not accept the standard 4mm O-ring seal. Instead, an oversized 5mm seal must be used. Pumps that require a 5mm seal are stamped with a "5" on the water pump bolt flange area. Make sure that you use the proper O-ring seal when installing the water pump.

  1. Drain the cooling system.
  2.  
  3. Remove the alternator and drive belt.
  4.  
  5. Remove the timing belt cover.
  6.  
  7. Disconnect the lower radiator hoses, engine hose and heater hose from the water pump.
  8.  
  9. Remove the pump retaining bolts. Note where the different length bolts are located, for installation.
  10.  
  11. Turn the pump slightly and lift it out of the engine block. If the pump is stubborn, tap around the edges of the pump with a rubber mallet to loosen it, then separate the pump from the pump housing. Clean the pump housing gasket surface to remove all traces of the gasket material. Remove the pump pulley and transfer it to the new pump.
  12.  

To install:
  1. Install a new O-ring seal into the pump. Make sure the seal seats evenly in the groove. Lubricate the seal with a liberal coat of silicone compound prior to installation.
  2.  
  3. Place the new pump gasket onto the pump housing and install the pump onto the gasket. Install one of the mounting bolts to hold the pump and gasket in place. Make sure all the gasket bolt holes are aligned properly with the holes in the housing before installing the remaining bolts. Torque the bolts to 7 ft. lbs. (10 Nm). Torque the pulley bolts to 15 ft. lbs. (20 Nm). It will be easier to torque the pulley bolts after the belt has been installed and tensioned.
  4.  
  5. Connect the heater, radiator and engine hoses.
  6.  
  7. Install the timing belt cover.
  8.  
  9. Install the alternator and adjust the drive belt tension.
  10.  
  11. Fill the cooling system and connect the negative battery cable. Start the engine and check for leaks.
  12.  

 
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