How to Repair a Water Pump in a 1998 Volkswagon Beetle

The car's water pump sends coolant into the engine, preventing it from overheating. Replacing a water pump on the new Volkswagen Beetle is challenging because both the drive belt and timing belt must be removed. Consult with your mechanic before you take this task on. Also, the engine needs to be cool before you begin.

Instructions

Accessing the Pump

1

Raise the car and support it on jack stands. Block the rear wheels, make sure the parking brake is on and remove the right front wheel.

2

Drain the engine coolant--place a large container under the radiator drain plug, attach a hose to the drain fitting and open the fitting; this may take pliers. After draining the coolant from the radiator, drain the rest from the engine oil cooler.

3

Relieve the fuel pressure--remove Fuse 28 from the fuse box, open the fuel cap, start the engine, look for it to stall and crank it for three more seconds.

4

Remove the drive belt--rotate the tensioner with a long 15-millimeter wrench, slip the belt off the pulleys and slowly release the tensioner.

5

Unclip the upper timing belt cover. Attach a large socket and breaker bar to the crankshaft pulley center bolt and rotate the engine clockwise until the number one cylinder is at the Top Down Center Position. Make sure the camshaft sprocket mark aligns with the rear timing belt cover's mark, then hold the crankshaft pulley with a strap wrench.

6

Disconnect the spark plugs--pull out the spark plug wire by the boot and remove the plug with a ratchet and spark plug socket.

7

Remove the timing belt--support the engine with a floor jack and block of wood, remove the passenger-side engine mount and support bracket, remove the remaining timing belt covers and release the tensioner by loosening the retaining nut and rotating the tensioner.

Changing the Pump

8

Detach any of the idler pulleys that would interfere with the water pump's removal.

9

Unbolt the water pump and remove it from the engine block.

10

Clean the mating surface of the engine block; apply acetone or lacquer thinner with a rag. Make sure the mating surface on the replacement water pump is clean also.

11

Install a new O-ring to the water pump and apply a small amount of engine coolant to the O-ring.

12

Install the water pump onto the engine block and tighten the bolts to 132 inch-pounds.

13

Re-install the idler pulleys, timing belt, drive belt and all other components. The crankshaft must still be set at the TDC position with the camshaft sprocket aligned with the rear timing belt cover. Rotate the engine two full turns and reset the engine to TDC.

14

Add engine coolant to the specified level in the radiator and reservoir. Use a fresh mix of water and antifreeze (50/50) if the old coolant is dirty. Re-connect the fuse for the fuel system also.