Replacing water pump

1
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
2

Jon,

This was discussed recently in a lot of detail.  From memory, Ken posted the most comprehensive information, so have a look back through the posts.

Les

 

From: Syncro_T3_Australia@yahoogroups.com [mailto: Syncro_T3_Australia@yahoogroups.com ] On Behalf Of Jon Elliott
Sent: 10 December 2011 13:53
To: Syncro T3 Australia
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

3
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

4
Scott
Thanks for the tips. I see what you mean about the Allen screws. I have released the air conditioner compressor and moved it to one side, removed the mounting plate (which could also be used for an anchor) and spent an hour trying to lock the pulley so that I can undo the remaining screw and be able to get at the pump. Still haven't managed to undo it!
Is there a preferable sequence in disconnecting the fittings to the pump and how much coolant is lost? What do you use on the screw threads to keep them from freezing up? Any advice would be appreciated.
JonE

From: Scott Daniel - Turbovans <ScottDaniel@turbovans.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Saturday, 10 December 2011 3:50 PM
Subject: Re: [Syncro_T3_Australia] Replacing water pump

 
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


5
Scott
Thanks for the tips. I have managed to remove the water pump and it was not as hard a job as expected. I got to the stage of undoing the Allen screws and the future looked bleak until my son arrived and removed all the screws in 15 minutes with his technique of using a ring spanner slipped over the 90 degree end of the Allen key to act as a lever. Now to put the new pump in!!!!
Regards
JonE

From: Scott Daniel - Turbovans <ScottDaniel@turbovans.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Saturday, 10 December 2011 3:50 PM
Subject: Re: [Syncro_T3_Australia] Replacing water pump

 
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


6
Scott
Thanks for the tips. The Allen screws did not give too much of a problem once my son provided his selection of long Allen keys and showed me how to use a ring spanner fitted over the 90 degree end of the key to provide leverage. Patience is required - don't lose your temper!
The pump is out and I am about to put the new one in. I'll have to wait for replacement hoses for some I noticed were in bad condition. What did you use on the threads to stop them freezing up?
All of this is a warm-up for putting in my new decoupler.
Regards
JonE
7

sounds like good progress ..
if you're asking me ..
I use ......on screw threads to keep them from corroding in place ...
Permatex High Tach gasket sealer ...the red stuff, in the can with a brush in the cap .
 
or ...aluminum anti-seize compound.
or ........copper anti-seize compound.
 
the gasket sealer sure works well...
sticks 'em , anti-vibration wise..
and prevents corrosion ..
they come out years later nice.
 
Scott
----- Original Message -----
Sent: Monday, December 12, 2011 6:05 PM
Subject: [Syncro_T3_Australia] Replacing water pump

 

Scott
Thanks for the tips. The Allen screws did not give too much of a problem once my son provided his selection of long Allen keys and showed me how to use a ring spanner fitted over the 90 degree end of the key to provide leverage. Patience is required - don't lose your temper!
The pump is out and I am about to put the new one in. I'll have to wait for replacement hoses for some I noticed were in bad condition. What did you use on the threads to stop them freezing up?
All of this is a warm-up for putting in my new decoupler.
Regards
JonE