Coolant pump — removal and installation (VW Lt 28)

Removal the pump

Before removing the coolant pump, the cooling system must be drained.

• Remove the vacuum pump V-belt, which can be done after removing the outer disc.
• Remove the metal gear guard.

In a Volkswagen engine, the front timing belt must be removed. To avoid possible installation errors, it is recommended to set the engine to the injection start position in the 1st cylinder and to do this, align the fuel pump alignment marks in a single line. The mark on the flywheels must be positioned opposite the mark in the clutch housing (see drawing in p. 2.2.9 "Injection system").

• Lock the front camshaft gear to loosen the mounting bolt one turn.
• Loosen the coolant pump mounting bolts to remove tension from the timing belt.
• Using a puller or a metal apron, separate the front gear from the camshaft.
• Remove the gear and timing belt, then the rear metal cover.

Please note: The designer did not provide spare parts for repairing the coolant pump. In case of leaks or gaps in the roller, the entire pump unit must be replaced.

Installation

• Thoroughly clean the inside of the coolant pump housing. A circular ring ensures tightness between the crankcase and the pump. When the pump moves and the toothed belt is tensioned, the ring slips in the crankcase, and the resulting leakage can cause a leak.
• Install the fluid pump in the crankcase without tightening the bolts.
• Install the rear metal timing belt cover.
• Install the gear with the toothed belt on the camshaft, but do not tighten the bolts. The gear must rotate on the camshaft.
• Check if the crankshaft has turned; the mark on the flywheel should be opposite the mark on the clutch housing.
• Make sure that the camshaft does not rotate; the marks on the fuel pump must be aligned.
• Tighten the timing belt by turning the coolant pump and then tighten the bolts securing the pump. Using a special device, check the belt tension (see section 2.2.6 "Distribution system").
• Using a special lever, lock the front camshaft gear and tighten the gear bolts to the appropriate torque.

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Important! If you are unsure of the camshaft position, we recommend checking its alignment using a 4.5 mm gauge.

• Check whether the fuel pump is always in the position marked on the flywheel in the TDC position. Otherwise, it is necessary to install the distribution after removing both gears of the distribution shaft (see point 2.2.6 "Distribution system").
• Install the alternator and vacuum pump V-belt. Belt tension is achieved by installing more or fewer shims between the two discs.
• Fill the system with coolant.

Attention! Coolant is a mixture of water and G10 antifreeze with anti-corrosion properties. This liquid prevents water from freezing, corrosion, retains limescale deposits and increases the boiling point of water. For proper engine operation, it is recommended to use this fluid all year round, even in tropical conditions.

Thermostat

The thermostat is located in the horizontal outlet of the coolant pump housing, the mark on the outer part should be facing up and out.