Contents: Extraction ↓ Disassembling the pump ↓
Extraction
1. Drain the fluid from the cooling system.
2. Remove the generator.
3. On vehicles equipped with power steering, the auxiliary pump and bracket will need to be removed to access the water pump. On vehicles equipped with air conditioning, the compressor assembly and bracket will need to be removed.
Caution: Do not disconnect the air conditioning system wires.
To remove the water pump from the 1.6D engine, you must first remove the injection pump as described in Section 1, otherwise there will be no access to the upper bolts securing the generator bracket.
3. Disconnect the three rubber coolant hoses from the pump, then unscrew and remove the four bolts securing the generator bracket and water pump. To remove the pump from the block, tap it with a copper hammer. Remove the o-ring together with the pump.
Disassembling the pump
4. Remove the pulley and unscrew the eight bolts that secure the bearing cover and impeller to the water pump housing. Remove the bearing cover with the impeller (photo 2.16). Do not use a screwdriver to pry the water pump cover off. Remove the old gasket.
5. Remove the thermostat.
6. The most frequently damaged elements in a water pump are the bearing, shaft seal or impeller. If any element is damaged, all three of the above must be replaced.
Pump installation
7. Cover the sealed surfaces with waterproof liquid and install a new gasket. Fit the two parts of the water pump and tighten the bolts evenly with a torque of 10 Nm. Secure the thermostat.
Installation
The pump is installed on the engine in the reverse order of removal.
The original can be viewed on the portal VWmanual
1. First, you need to put on a new O-ring. Then put on the pump and install the generator bracket and screw it with four bolts. Tighten the bolts to a torque of 20 Nm (photo 2.18).
2. Put on the generator and tighten the V-belt.
3. Fill the cooling system with liquid.
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