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How to change water pump & timing belt kit on VW Jetta Mk5 (1K) – replacement guide

downloads: 19

Recommended replacement interval for the part category Water pump and timing belt kit : 70000 km

Important!

This replacement procedure can be used for:
VW Jetta Mk5 (1K) 2.0 TFSI … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Water Pump + Timing Belt Kit for Jetta Mk5 (1K) and other VW models

Alternative products

Water pump and timing belt kit

Replacement: water pump & timing belt kit – VW JETTA III (1K2). List of the tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      All-purpose cleaning spray
                    
                      Sealant
                    
                      Torque wrench
                    
                      Combination spanner #13
                    
                      Combination spanner #17
                    
                      Combination spanner #19
                    
                      Combination spanner #22
                    
                      Torx bit T20
                    
                      Torx bit T25
                    
                      Torx bit T27
                    
                      12-point socket # 19
                    
                      Drive socket # 7 
                    
                      Drive socket # 10 
                    
                      Drive socket # 12 
                    
                      Drive socket # 13 
                    
                      HEX bit No.H6
                    
                      HEX bit No.H8
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Tap wrench
                    
                      Clip removal tool
                    
                      Flat Screwdriver
                    
                      Phillips screwdriver
                    
                      Crow bar
                    
                      Water pump pliers
                    
                      Clic-R collar pliers
                    
                      Round-nose pliers
                    
                      Seal scraper
                    
                      Funnel
                    
                      Fluid container
                    
                      Hydraulic transmission jack
                    
                      Jack
                    
                      Painter's tape
                    
                      Microfibre towel
                    
                      Fender cover

Buy tools

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip from AUTODOC experts:

Follow the terms, recommendations and requirements of the part operation provided by the manufacturer.
Warning! Shut down the engine before starting any work – VW JETTA III (1K2).

Carry out replacement in the following order:

Step 1

Open the bonnet.

Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.

Step 3

Unscrew the fasteners of the car battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 4

Remove the battery terminals.
Step 5

Unscrew the coolant reservoir cap.
Step 6

Loosen the bumper upper fasteners. Use Torx T27. Use a drive socket #10. Use a ratchet wrench.
Step 7

Lift the car using a jack or place it over an inspection pit.

Step 8

Unscrew the wheel bolts. Use wheel impact socket #17.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW JETTA III (1K2)
Step 9

Remove the wheel.
Step 10

Unscrew and remove the wheel arch cover fasteners. Use Torx T25. Use a ratchet wrench.
Step 11

Remove the wheel arch cover.
Step 12

Unscrew the fastener of the spacer under the bumper reinforcement bar. Use Torx T25. Use a drive socket #10. Use a ratchet wrench.
Step 13

Unscrew the fastener connecting the bumper to the fenders. Use a drive socket #10. Use a ratchet wrench.
Step 14

Release the side clips of the bumper. Carefully release the bumper from the fasteners.
Step 15

Lower the car.

Step 16

Unscrew the upper fasteners of the bumper and remove it. Use Torx T27. Use a drive socket #10. Use a ratchet wrench.
Step 17

Detach the connectors of the fog lights.
Step 18

Detach the headlamp washer hose.
Step 19

Unscrew the headlight fasteners. Use Torx T27. Use a ratchet wrench.
Step 20

Remove the headlight.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip from AUTODOC:
Do not apply excessive force when removing the part. Otherwise you may damage it.
Step 21

Unplug the connectors of the headlight bulbs. Use a clip removal tool.
Step 22

Unscrew the headlight fasteners. Use Torx T27. Use a ratchet wrench.
Step 23

Remove the headlight.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). AUTODOC recommends:
Do not apply excessive force when removing the part. Otherwise you may damage it.
Step 24

Unplug the connectors of the headlight bulbs. Use a clip removal tool.
Step 25

Unplug the horn connector.
Step 26

Detach the air duct.
Step 27

Unplug the horn connector.
Step 28

Remove the air duct.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip:
Do not apply excessive force when removing the part. Otherwise you may damage it.
Step 29

Unplug the connector of the coolant temperature sensor.
Step 30

Detach the wiring of the coolant temperature sensor. Use a flat screwdriver.
Step 31

Unscrew the fasteners of the bumper reinforcement bar. Use a drive socket #13. Use a ratchet wrench.
Step 32

Remove the bumper reinforcement bar.
Step 33

Unscrew the fasteners of the radiator air guides. Use Torx T20. Use a ratchet wrench.
Step 34

Remove the radiator air guides.
Step 35

Unscrew the fasteners of the hydraulic power steering hoses. Use Torx T20. Use Torx T27. Use a ratchet wrench.
Step 36

Detach the hydraulic power steering hoses.

Step 37

Prepare a container for fluids.
Step 38

Open the coolant drain tap. Use water pump pliers.
Step 39

Drain the coolant from the engine.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Professionals recommend:
Caution! The coolant can be very hot.Wear gloves to prevent contact with hot liquid.All work should be done with the engine stopped.
Step 40

Close the coolant drain tap.

Step 41

Detach the clip of the lower coolant hose. Use a clip removal tool.

Step 42

Detach the lower coolant pipe. Use a crowbar.
Step 43

Detach the air intake hose clamp. Use a drive socket #7. Use a ratchet wrench.
Step 44

Remove the air intake pipe.
Step 45

Cover the intercooler air guide with a microfibre cloth to prevent dirt and foreign objects from getting into the system.
Step 46

Detach the air intake hose clamp. Use a drive socket #7. Use a ratchet wrench.
Step 47

Clean the air hose fastener. Use all-purpose cleaning spray.
Step 48

Detach the air intake hose clamp. Use a drive socket #7. Use a ratchet wrench.
Step 49

Remove the air intake pipe.
Step 50

Cover the intercooler air guide with a microfibre cloth to prevent dirt and foreign objects from getting into the system.
Step 51

Prepare a container for fluids.
Step 52

Loosen the fastener of the hose of the automatic transmission fluid cooling line. Use a combination spanner #19. Use a combination spanner #22.
Step 53

Detach the hose of the automatic transmission fluid cooling line.
Step 54

Clean the hose of the automatic transmission fluid cooling line. Use a wire brush. Use all-purpose cleaning spray.
Step 55

Detach the clamps of the pipes of the automatic transmission fluid cooling line. Use a flat screwdriver.
Step 56

Remove the pipes of the automatic transmission fluid cooling line.
Step 57

Close the pipes of the automatic transmission fluid cooling line with caps.
Step 58

Clean the pipes of the automatic transmission fluid cooling line. Use all-purpose cleaning spray.
Step 59

Unscrew the fasteners of the air intake duct. Use a Phillips screwdriver.
Step 60

Remove the air intake duct.
Step 61

Unplug the connector of the engine cooling fans.
Step 62

Remove the wiring harness holder.
Step 63

Unplug the connector of the engine cooling fans.
Step 64

Detach the clip of the upper coolant hose. Use round-nose pliers.
Step 65

Detach the upper coolant hose.
Step 66

Remove the bonnet weather strip.
Step 67

Unscrew the fasteners of the air conditioning radiator. Use Torx T27. Use a ratchet wrench.
Step 68

Remove the air conditioning radiator.
Step 69

Unscrew the fasteners of the engine cooling radiator support panel. Use Torx T27. Use a ratchet wrench.
Step 70

Remove the bonnet latch cable.
Step 71

Support the engine in the oil pan area. Use a jack.
Step 72

Remove the support panel together with the engine cooling radiator.

AUTODOC recommends:
Replacement: water pump & timing belt kit – VW JETTA III (1K2). Do not use excessive force when removing the part as this may damage it.
Step 73

Remove the support from under the engine.
Step 74

Remove the engine cover.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). AUTODOC recommends:
Raise the engine cover, holding it on two sides simultaneously.Do not apply excessive force when removing the part. Otherwise you may damage it.
Step 75

Unscrew the fasteners of the front upper timing belt cover. Use a flat screwdriver.
Step 76

Remove the front upper timing belt cover.
Step 77

Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #17.
Step 78

Remove the V-ribbed belt.
Step 79

Return the tensioner pulley to its initial position. Use a combination spanner #17.
Step 80

Unscrew the fastener of the serpentine belt tensioner pulley. Use a drive socket #13. Use a ratchet wrench.
Step 81

Remove the serpentine belt tensioner pulley.
Step 82

Unscrew the fastener of the coolant hose clamp. Use HEX No.H6. Use a ratchet wrench.
Step 83

Loosen the coolant hose clamp. Use clic-R collar pliers.
Step 84

Detach the coolant hose.
Step 85

Unscrew the fasteners of the timing belt cover. Use a drive socket #10. Use Torx T27. Use a ratchet wrench.
Step 86

Remove the timing belt cover.
Step 87

Clean the crankshaft pulley fasteners. Use a wire brush. Use WD-40 spray.
Step 88

Unscrew the crankshaft pulley fastener. Use HEX No.H6. Use a ratchet wrench.
Step 89

Turn the crankshaft gear. Use 12-point socket No.19. Use a tap wrench.
Step 90

Lock the crankshaft. Use a crowbar.
Step 91

Remove the crankshaft pulley.
Step 92

Unscrew the fasteners of the lower timing cover. Use a drive socket #10. Use a ratchet wrench.
Step 93

Remove the lower timing cover.

Step 94

Make a mark on the crankshaft gear.
Step 95

Make a mark on the camshaft gear.
Step 96

Make a mark on the timing belt.
Step 97

Loosen the fastener of the timing belt tensioner pulley. Use a combination spanner #13. Use HEX No.H8.
Step 98

Unscrew the fastener of the timing belt idler pulley. Use a drive socket #13. Use a ratchet wrench.
Step 99

Remove the timing belt idler pulley from its mounting seat.
Step 100

Unscrew the fastener of the timing belt idler pulley. Use a drive socket #12. Use a ratchet wrench.
Step 101

Remove the timing belt idler pulley from its mounting seat.
Step 102

Remove the timing belt tensioner pulley.
Step 103

Remove the timing belt.
Step 104

Clean the water pump fasteners. Use a wire brush. Use all-purpose cleaning spray.
Step 105

Unscrew the water pump fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 106

Remove the water pump.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). AUTODOC experts recommend:
Caution! Coolant may come out from the water pump channels and body.
Step 107

Clean the water pump mounting seat. Use a seal scraper. Use all-purpose cleaning spray.
Step 108

Clean the water pump. Use all-purpose cleaning spray.
Step 109

Treat the water pump mounting seat. Use a sealant.

Step 110

Install the new water pump.
Step 111

Screw in the water pump fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 112

Tighten the water pump fasteners. Use a drive socket #10. Use a torque wrench. Tighten it to 15 Nm torque.
Step 113

Install the new timing belt according to the factory marks.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip:
Be careful not to damage the timing belt.
Step 114

Install the timing belt tensioner pulley.
Step 115

Treat the fastening bolt. Use a sealant.
Step 116

Screw in the fastener of the timing belt tensioner pulley. Use a drive socket #13. Use a ratchet wrench.
Step 117

Treat the fastening bolt. Use a sealant.
Step 118

Install the timing belt idler pulley.
Step 119

Screw in the fastener of the timing belt idler pulley. Use a drive socket #12. Use a ratchet wrench.
Step 120

Treat the fastening bolt. Use a sealant.
Step 121

Install the timing belt idler pulley.
Step 122

Screw in the fastener of the timing belt idler pulley. Use a drive socket #13. Use a ratchet wrench.
Step 123

Tighten the fastener of the timing belt idler pulley. Use a drive socket #13. Use a torque wrench. Tighten it to 25 Nm torque.
Step 124

Tighten the fastener of the timing belt idler pulley. Use a drive socket #12. Use a torque wrench. Tighten it to 25 Nm torque.
Step 125

Adjust the timing belt tension by moving the tensioner pulley. Use a combination spanner #13. Use HEX No.H6.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip from AUTODOC:
Make sure that the timing belt is properly tensioned.
Step 126

Remove the crankshaft locking tool.
Step 127

Turn the crankshaft gear. Use 12-point socket No.19. Use a ratchet wrench.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). AUTODOC recommends:
Make sure all the timing belt components are mounted correctly.
Step 128

Tighten the fastener of the timing belt tensioner pulley. Use a drive socket #13. Use a torque wrench. Tighten it to 27 Nm torque.
Step 129

Install the lower timing cover.
Step 130

Tighten the fasteners of the lower timing cover. Use a drive socket #10. Use a torque wrench. Tighten it to 10 Nm torque.
Step 131

Install the timing belt cover.
Step 132

Tighten the timing belt cover fasteners. Use a drive socket #10. Use Torx T27. Use a torque wrench. Tighten it to 10 Nm torque.
Step 133

Attach the coolant hose.
Step 134

Secure the coolant hose clamp. Use clic-R collar pliers.
Step 135

Screw in the fastener of the coolant hose clamp. Use HEX No.H6. Use a ratchet wrench.
Step 136

Treat the fastening bolts. Use a sealant.
Step 137

Install the crankshaft pulley according to the factory marks.
Step 138

Tighten the crankshaft pulley fastener. Use HEX No.H6. Use a torque wrench. Tighten it to 10 Nm torque.+90°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 139

Treat the fastening bolts. Use a sealant.
Step 140

Install the serpentine belt tensioner pulley.
Step 141

Tighten the fastener of the serpentine belt tensioner pulley. Use a drive socket #13. Use a torque wrench. Tighten it to 23 Nm torque.
Step 142

Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #17.
Step 143

Install the V-ribbed belt.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip:
Make sure that the V-ribbed belt fits all pulleys snugly.
Step 144

Return the tensioner pulley to its initial position. Use a combination spanner #17.
Step 145

Support the engine in the oil pan area. Use a jack.
Step 146

Install the support panel together with the engine cooling radiator.

AUTODOC recommends:
Replacement: water pump & timing belt kit – VW JETTA III (1K2). Do not use excessive force during installation. This may damage the fasteners.
Step 147

Screw in the fasteners of the engine cooling radiator support panel. Use Torx T27. Use a ratchet wrench.
Step 148

Install the air conditioning radiator.
Step 149

Tighten the fasteners of the air conditioning radiator. Use Torx T27. Use a torque wrench. Tighten it to 13 Nm torque.
Step 150

Remove the support from under the engine.
Step 151

Attach the lower coolant pipe.
Step 152

Attach the clip of the lower coolant hose.

Step 153

Install the pipes of the automatic transmission fluid cooling line.

Step 154

Attach the clamps of the pipes of the automatic transmission fluid cooling line.

Step 155

Prepare a container for fluids.
Step 156

Remove the caps from the pipes of the automatic transmission fluid cooling line.
Step 157

Attach the hydraulic power steering hoses.
Step 158

Screw in the fasteners of the hydraulic power steering hoses. Use Torx T20. Use Torx T27. Use a ratchet wrench.
Step 159

Remove the microfibre cloth from the intercooler air guide.
Step 160

Install the air intake pipe and secure it.
Step 161

Fasten the clamp on the air intake hose. Use a drive socket #7. Use a ratchet wrench.
Step 162

Clean the pipes of the automatic transmission fluid cooling line. Use all-purpose cleaning spray.
Step 163

Attach the hose of the automatic transmission fluid cooling line.
Step 164

Tighten the fastener of the hose of the automatic transmission fluid cooling line. Use a combination spanner #19. Use a combination spanner #22. Use a torque wrench. Observe the recommended tightening torque.
Step 165

Remove the microfibre cloth from the intercooler air guide.
Step 166

Install the air intake pipe and secure it.
Step 167

Fasten the clamp on the air intake hose. Use a drive socket #7. Use a ratchet wrench.
Step 168

Plug in the connector of the engine cooling fans.
Step 169

Fasten the clamp on the air intake hose. Use a drive socket #7. Use a ratchet wrench.
Step 170

Install the bonnet latch cable.
Step 171

Install the wiring harness holder.
Step 172

Attach the upper coolant hose.
Step 173

Attach the clip of the upper coolant hose.
Step 174

Plug in the connector of the engine cooling fans.
Step 175

Install the radiator air guides.

Step 176

Screw in the fasteners of the radiator air guides. Use Torx T20. Use a ratchet wrench.
Step 177

Install the bonnet weather strip.
Step 178

Install the bumper reinforcement bar.
Step 179

Screw in the fasteners of the bumper reinforcement bar. Use a drive socket #13. Use a ratchet wrench.
Step 180

Lift the car using a jack or place it over an inspection pit.

Step 181

Support the bumper reinforcement bar. Use a hydraulic transmission jack.
Step 182

Tighten the fastener of the bumper reinforcement bar. Use a drive socket #13. Use a torque wrench. Observe the recommended tightening torque.
Step 183

Remove the support from under the bumper reinforcement bar.

AUTODOC recommends:
Replacement: water pump & timing belt kit – VW JETTA III (1K2). Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 184

Plug in the horn connector.

Step 185

Attach the air duct.

Step 186

Plug in the horn connector.

Step 187

Install the air duct.
Step 188

Plug in the connector of the coolant temperature sensor.
Step 189

Attach the wiring of the coolant temperature sensor.
Step 190

Plug in the connectors of the headlight bulbs.
Step 191

Install the headlamp.
Step 192

Screw in the headlight fasteners. Use Torx T27. Use a ratchet wrench.
Step 193

Plug in the connectors of the headlight bulbs.
Step 194

Install the headlamp.
Step 195

Screw in the headlight fasteners. Use Torx T27. Use a ratchet wrench.
Step 196

Tighten the headlamp fasteners. Use Torx T27. Use a torque wrench. Observe the recommended tightening torque.
Step 197

Install the front upper timing belt cover.
Step 198

Screw in the fasteners of the front upper timing belt cover. Use a flat screwdriver.
Step 199

Install the air intake duct.
Step 200

Screw in the fasteners of the air intake duct. Use a Phillips screwdriver.
Step 201

Stick painter's tape to the car fenders to protect the paintwork from damage when demounting the bumper.
Step 202

Attach the connectors of the fog lights.
Step 203

Attach the headlamp washer hose.
Step 204

Install the bumper to the mounting seat. Make sure you hear a click indicating that it is locked in place.
Step 205

Screw in the bumper upper fasteners. Use Torx T27. Use a drive socket #10. Use a ratchet wrench.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip:
To prevent damage to the components, hold the bumper when screwing in the upper fasteners.
Step 206

Snap the bumper side clips into place. Make sure you hear a click indicating that it is locked in place.
Step 207

Remove the masking tape.
Step 208

Screw in the fasteners connecting the bumper to the wings. Use a drive socket #10. Use a ratchet wrench.
Step 209

Screw in the fastener of the spacer under the bumper reinforcement bar. Use Torx T25. Use a drive socket #10. Use a ratchet wrench.
Step 210

Install the wheel arch cover to its mounting seat.
Step 211

Install and tighten the wheel arch cover fasteners. Use Torx T25. Use a ratchet wrench.
Step 212

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VW JETTA III (1K2)
Step 213

Screw in the wheel bolts. Use wheel impact socket #17.
Step 214

Lower the car.

Step 215

Secure the wheels with chocks.

Step 216

Tighten the wheel bolts using a criss-cross pattern. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 Nm torque.
Step 217

Remove the jacks and chocks.

Step 218

Remove the coolant reservoir cap.
Step 219

Insert the funnel.
Step 220

Pour coolant in the coolant reservoir.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Professionals recommend:
Only use the coolant recommended by the manufacturer.The coolant level should be at the MAX mark.Wait until the air goes out of the system.
Step 221

Open the coolant system bleed screw. Use a drive socket #10. Use a ratchet wrench. Wait until the air goes out of the system.
Step 222

Unscrew the cap of the hydraulic power steering reservoir. Remove the cap from the hydraulic power steering reservoir.
Step 223

Fill the hydraulic power steering reservoir with fluid.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). Tip from AUTODOC:
Use the hydraulic power steering fluid recommended by the car manufacturer.The hydraulic power steering fluid level should be at the MAX mark on the reservoir.
Step 224

Attach the terminals to the battery.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). AUTODOC recommends:
Be careful! Do not mix up the positive and the negative terminals of the car battery.
Step 225

Screw in the fasteners of the battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 226

Run the engine for a few minutes. This should be done in order to remove residual air from the cooling system and to check if the components are operating correctly.
Step 227

Shut off the engine.

Step 228

Check the coolant level. If necessary, top up to the required level.

Please note!
The coolant level should be at the MAX mark.
Step 229

Close the coolant system bleed screw. Use a drive socket #10. Use a ratchet wrench.
Step 230

Place the cap on the hydraulic power steering reservoir.
Step 231

Screw on the cap of the hydraulic power steering reservoir.

Step 232

Install the coolant reservoir cap.

Step 233

Screw on the coolant reservoir cap.

Step 234

Install the engine cover and secure it.

AUTODOC recommends:
Replacement: water pump & timing belt kit – VW JETTA III (1K2). Do not use excessive force during installation. This may damage the part.Make sure the engine cover is properly seated. It should not be displaced with respect to the guiding fasteners.
Step 235

Remove the fender protection cover.

Step 236

Close the hood.

Replacement: water pump & timing belt kit – VW JETTA III (1K2). AUTODOC experts recommend:
Be sure to record the mileage at which you replaced the timing belt and water pump kits.

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