Water pump removal BHW engine - 2004 2005 VW Passat TDI

difficulty: 2/5
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Introduction

This article shows how to remove the water pump on a VW Passat TDI 2004 2005.  It should be changed every 100,000 miles along with the timing belt.

I suggest a metal impeller water pump because the plastic OEM VW pump sometimes slips on the impeller shaft.  This will produce overheating with no other symptoms.  If the impeller slips on the shaft no coolant will circulate and the car will overheat. 

Parts

water pump VW# 038 121 011 j worldimpex generic, ecstuning

Note: most of the timing belt parts are the same as a BRM engine (2005.5-2006 VW Jetta TDI).  The water pump is different.  I don't know why since it looks the same.

DIY water pump replacement procedure

Remove the timing belt.  Refer to 1000q: timing belt part 1 - B5.5 Passat TDI for more details.

Drain the radiator by put a hose on the radiator drain and then loosening the drain screw - it's plastic so be careful.  (bumper removed for illustration)  Open the coolant reservoir cover to help the coolant drain out.  Only about 80% of the coolant will drain this way, I suggest doing a full flush now.  See 1000q: coolant flush Passat TDI for more details and steps.

Remove the 3x 10mm bolts holding the water pump.

If the water pump is stuck, use a piece of wood or rubber mallet to gently tap on the top and bottom until the water pump is loose.  Don't smack it with a metal hammer or use a sharp pry because this will damage the sealing surfaces.  Dieselgeek sells water pump removal bolts which will help push a really stuck pump out.  Below is the 3x rusty bolt tolls being used on an older engine.

Have paper towels and a catch pan ready because there's lots of coolant that will come out.

Wipe the sealing area clean and make sure the old o-ring is removed.

To install the new water pump on your 2004 or 2005 VW Passat TDI, lubricate the new o-ring with some coolant and press the new pump in by hand.  Make sure to lubricate the o-ring or else it could get twisted or pinched, causing a coolant leak.  Don't use any liquid gasket maker.

Torque the 3x 10mm bolts to 11 ft lbs.

Here is a picture of the backside of a metal-impeller water pump.

Refer to 1000q: timing belt part 1 - B5.5 Passat TDI or 1000q: BHW engine timing belt part 2 for installation.

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