get ready for a real 'what were they not thinking' kind of job !
It's one of the least fun water pump jobs there is in the car world.
it's 5 hours by the time you're really done..
and that's even if you've done it before a few times.
if you don't find something online..
or get a run-down from other group members , I'll list some steps and tips for you.
one customer told me this..
in explanation of why it's so hard to do ..
he said VW told their engineers ...'you have 30 days to come up with a water-cooled version of our traditional opposed four aluminum engines.'
and that fits too.
it's very easy while assembling the engine out of the van .
in the van ..
and especially if Allen screws are corroded or stuck in ( I'm super big on putting something on the threads of all water pump and other screws to make them come out easily years later .......I'm fanatical about that ) ...
heck, I have spent well over an hour on the lower 6 mm Allen screw on the side of the water pump toward the crankshaft pulley. Over an hour on 'one screw' !
I don't put those Allen screws back in ..
I replace them with hard-to-find 8 X 1.25 metric screws of the right length ..with a 10 mm hex head ..
and I get 12mm hex head ones off Japanese cars ..
those work nicely too. Using an allen there is just dumb..
and I never see anyone install screws like that except bare metal-to-metal ..
and then they're badly stuck in years later.
it's all about the workmanship. The impeccable detail workmanship.
Scott
----- Original Message -----
Sent: Friday, December 09, 2011 6:52 PM
Subject: [Syncro_T3_Australia] Replacing water pump
I have purchased a new water pump from Tooleys and am about to install it. The Bentley repair manual shows the parts involved but does not indicate any sequence of steps for removal and installation. Does any member know of any instruction sheet available to make things easier for a mechanical klutz to do the job?
Regards
JonE