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Waterpump/Thermostate Replacement DIY

MKVjoe

Ready to race!
Location
Meriden, CT
I will be writing up and photographing the water-pump/thermostat housing replacement on my 09' MKV GTI TSI - Eng. Code CCTA. I will be using the Chilton Repair Online Manual as a general guideline for the replacement of the pump.

Here is some of the background info i found on the coolant system and water-pump replacement.

Coolant System Overview: View attachment VW MKV GTI Coolant System.pdf

Water-Pump/Thermostat Replacement: View attachment VW MKV GTI Water-Pump Replacement.pdf

I will be supplementing the above info with my own write up and photos of the job once i receive parts on Thursday.
 

MKVjoe

Ready to race!
Location
Meriden, CT
OK...time for the run down.

Tools Needed: Ratchet 1/4-3/8, Breaker Bar or Long Bar Torque Wrench, Metric Sockets 7mm-24mm, Torex Heads from T10-T50, Needle Nose Pliers

Parts Needed: New Water Pump, New Hardware, New Drive Belt, Gallon of VW Antifreeze (See attached parts List Above)



-Well first we start with the obvious get the car on the lift or jack stands and disconnect battery.
http://sphotos-b.xx.fbcdn.net/hphotos-ash3/29615_479702708738198_745642544_n.jpg

-Then i removed the front part of my intake which would differ from OEM to aftermarket so i wont get into details

-Then i removed my catch can and the noise pipe on passenger side of motor. Noise pipe was just two clamps you squeeze with pliers and one torex that held noise pipe to bracket above alternator

http://sphotos-b.xx.fbcdn.net/hphotos-ash4/377893_479703215404814_118045977_n.jpg

-Next i got under car and removed plastic shield under engine which was held in my 6-8 torex heads

-While i was there i removed the after run coolant pump, there is one bolt on the right side of the electric pump to get it separated from bracelet then just two squeeze clamps and the hoses pulled right off, be sure to have a bucket or something to catch the antifreeze that will pour out.
http://sphotos-b.xx.fbcdn.net/hphotos-prn1/66471_485006488207820_1972830427_n.jpg
http://sphotos-a.xx.fbcdn.net/hphotos-snc7/479702_485006491541153_389809066_n.jpg

After some of the coolant drained i disconnect the after run pump and put to the side.
http://sphotos-a.xx.fbcdn.net/hphotos-ash3/538050_485012081540594_1035616378_n.jpg

-Next it was time to get the charge pipe connected to TB out, so i unbolted the MAS sensor which was held in by two Torex heads, and removed that. There was also two torex heads holding the charge pipe to block so i removed those as well. Then i used a socket to loosen the two clamps at each end of the charge pipe. Once i got those loose and after a little maneuvering i was able to remove the pipe out the bottom.

-Then i went back into engine-bay unplugged the TB and removed the (4) T30 torex holding it to manifold
http://sphotos-b.xx.fbcdn.net/hphotos-ash3/47670_485017348206734_844011051_n.jpg

-After the TB was removed i unbolted the plastic bracket hanging under drive side of intake manifold and unplugged the three connectors and slide then off bracket
http://sphotos-a.xx.fbcdn.net/hphotos-ash4/252068_485018181539984_682349942_n.jpg

-Next i followed the harness attached to the bracket i just mentioned above and started unplugging starting from left side of motor to right some of these connection included the TB you already unplugged and the Temp sender you need to unplug to remove water pump. Once these are all unplugged you should be able to move the harness toward the trans and out of the way

-Then i removed the coolant lines which ran from after run pump to expansion tank which was just squeeze clamps then a a small plastic hard line that wrapped around right side of motor which was just bolted to block and water pump with torex heads.
http://sphotos-b.xx.fbcdn.net/hphotos-ash3/541782_485025034872632_971479377_n.jpg
http://sphotos-a.xx.fbcdn.net/hphotos-ash4/394934_485025038205965_1108957362_n.jpg

-After these were out of my way i placed another bucket under car and removed both upper and lower coolant lines from pump which was just held in with a clip on each hose. Then i unbolted the belt cover on right side of pump again just two torex heads and the cover slides off to expose the drive belt and gears.
http://sphotos-a.xx.fbcdn.net/hphotos-ash3/63593_482857698422699_648680965_n.jpg
 

MKVjoe

Ready to race!
Location
Meriden, CT
will finish this in am guys, i left the rest of my notes at home
 

MKVjoe

Ready to race!
Location
Meriden, CT
-Once the belt drive was exposed, to remove the belt you need to put a 24mm socket with your breaker bar or torque wrench on the dampner then a 12 mm wrench on the bolt holding lower drive gear in, this bolt is reverse thread. But once you get it out the lower gear and drive belt fall right into your hands.
http://sphotos-a.xx.fbcdn.net/hphotos-ash3/602706_485278241513978_2105249274_n.jpg


-Next before you unbolt the pump itself you need to remove the brace just to the left of the pump which was a T50 torex holding it to block then a 12mm nut holding it to underside of manifold
http://sphotos-b.xx.fbcdn.net/hphotos-ash4/486279_485278248180644_2126979297_n.jpg

-Now that the pump is fully exposed you can unbolt the (5) t30 torex holding it to block, once these bolts were undone to get pump out pull toward you on the gear side and then pull towards trans to get it disconnected from coupler that joins it to oil cooler. this will take a little patience to shimmy it out.
http://sphotos-b.xx.fbcdn.net/hphotos-snc6/735184_485278251513977_841318805_n.jpg

-Now to get the new pump in, you need to slide the new black coupler with orings into oil cooler, i took some of the old antifreeze to wet the orings so it would slide in easier. Then slide pump into coupler and get it into place using the opposite motion used to take it out.

-Pop in your five new bolts and torque to the sequence in the chiltons manual in my first post. Then put your 24mm socket back on dampner and install your new drive belt and old gear again remember the bolt holding gear is reverse thread and before you replace cover over belt be sure to remove yellow cap off cooling fins on new pump.
http://sphotos-b.xx.fbcdn.net/hphotos-snc7/427633_485278298180639_1996709506_n.jpg

-Now reverse order for all the electrical and coolant connections top off coolant system with fresh antifreeze and test drive
 
Last edited:

caffeineTX

Ready to race!
Location
Houston
I will be writing up and photographing the water-pump/thermostat housing replacement on my 09' MKV GTI TSI - Eng. Code CCTA. I will be using the Chilton Repair Online Manual as a general guideline for the replacement of the pump.

Great DIY, thanks for posting this! saved because I am sure I will need it eventually.

some of the pics are missing any chance you can rehost them on imgur or something?
 

merkeyterkey

The Real FLATTIRE
Location
Pawnee, IN
OP, use imgur.com to host your pictures, that way they never expire...

I try and click the links now and it takes me to facebook and says content not found...
 

zrickety

The Fixer
Location
Unknown
Car(s)
VW GTI
There is a great how to for the TSI cars on golfmk6.
 

moonlightblue

New member
Location
Europe
Car(s)
Audi A5
OK...time for the run down.

-While i was there i removed the after run coolant pump, there is one bolt on the right side of the electric pump to get it separated from bracelet then just two squeeze clamps and the hoses pulled right off, be sure to have a bucket or something to catch the antifreeze that will pour out.
http://sphotos-b.xx.fbcdn.net/hphotos-prn1/66471_485006488207820_1972830427_n.jpg
http://sphotos-a.xx.fbcdn.net/hphotos-snc7/479702_485006491541153_389809066_n.jpg

After some of the coolant drained i disconnect the after run pump and put to the side.
http://sphotos-a.xx.fbcdn.net/hphotos-ash3/538050_485012081540594_1035616378_n.jpg

-Next it was time to get the charge pipe connected to TB out, so i unbolted the MAS sensor which was held in by two Torex heads, and removed that. There was also two torex heads holding the charge pipe to block so i removed those as well. Then i used a socket to loosen the two clamps at each end of the charge pipe. Once i got those loose and after a little maneuvering i was able to remove the pipe out the bottom.

-Then i went back into engine-bay unplugged the TB and removed the (4) T30 torex holding it to manifold
http://sphotos-b.xx.fbcdn.net/hphotos-ash3/47670_485017348206734_844011051_n.jpg

-After the TB was removed i unbolted the plastic bracket hanging under drive side of intake manifold and unplugged the three connectors and slide then off bracket
http://sphotos-a.xx.fbcdn.net/hphotos-ash4/252068_485018181539984_682349942_n.jpg

-Next i followed the harness attached to the bracket i just mentioned above and started unplugging starting from left side of motor to right some of these connection included the TB you already unplugged and the Temp sender you need to unplug to remove water pump. Once these are all unplugged you should be able to move the harness toward the trans and out of the way

I did not understand this part. And I can not see any picture. Could you please explain these steps?
 
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