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jess james View Drop Down
Newbie
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Joined: 12 Jan 08
Location: United Kingdom
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    Posted: 12 Jan 08 at 18:40
hi there

newbe here,my t5 died over xmas,water in oil?,garage said head gasket,tried that,still losing water , forum here thinks could be water pump,garage  has been trying to find out from vw where pump located,will not help them .any pics or drawings would help.

engine is 2.5L tdi 130 kombi.supurb work van.
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BigHerB View Drop Down
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Joined: 27 Nov 07
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Points: 8 		Post Options Post Options   Thanks (0) Thanks(0)   Quote BigHerB Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jan 08 at 22:05

This might help

 

 

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1 - 

Exhaust gas recirculation cooler

q  

Only vehicles with an automatic gearbox.

q  

Removing and installing ¡ú Chapter.

q  

Coolant hose schematic diagram ¡ú Chapter.

2 - 

10 Nm

3 - 

Upper coolant pipe

q  

Coolant hose schematic diagram ¡ú Chapter.

4 - 

Seal

q  

Renew.

5 - 

O-ring

q  

Renew.

6 - 

Coolant temperature sender -G62-

Repair work necessary to remove the coolant temperature sender -G62-:

t 

Bring lock carrier into service position ¡ú Rep. Gr.50.

t 

Remove intake manifold ¡ú Chapter

7 - 

Bracket

8 - 

10 Nm

9 - 

O-ring

q  

Renew

10 - 

Connection

q  

Coolant hose schematic diagram ¡ú Chapter.

11 - 

Gasket

q  

Renew.

q  

Note installation position.

12 - 

Lower coolant pipe

q  

Coolant hose schematic diagram ¡ú Chapter.

13 - 

Thermostat

q  

Note installation position.

q  

Checking: Heat up thermostat in water.

q  

Opening begins at approx. 80 ¡ãC.

q  

Ends at approx. 105 ¡ãC

q  

Opening lift min. 7 mm.

14 - 

Thermostat housing

q  

To remove, first remove connection from turbocharger ¡ú Item.

q  

Coolant hose schematic diagram ¡ú Chapter.

15 - 

Connecting hose

16 - 

Seal

q  

Renew.

17 - 

Coolant drain plug, 20 Nm

q  

Remove to remove coolant pump.

18 - 

Overflow hole, 20 Nm

q  

Up to engine code: ► AXD 010207 plug with overflow hole

q  

From engine code: AXD 010207 ► banjo bolt with drain hose

q  

Up to engine code: ► AXE 007588 plug with overflow hole

q  

From engine code: AXE 007588 ► banjo bolt with drain hose

q  

If coolant flows out at the plug with overflow hole or at banjo bolt with drain hose, the coolant pump must be renewed.

19 - 

Coolant pump

q  

Removing and installing ¡ú Chapter.

20 - 

25 Nm

21 - 

Cover

q  

For coolant pump.

q  

Renew seal if damaged.

q  

Lightly oil seal when installing.

22 - 

84 Nm

23 - 

Gear wheel

q  

For coolant pump.

q  

Check for damage.

24 - 

20 Nm + 1/4 turn (90¡ã) further

q  

Renew.

 

 

 

 

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Removing

¨C 

Drain coolant ¡ú Chapter.

¨C 

Unscrew coolant drain plug for coolant pump ¡ú Item.

¨C 

Unscrew plug with overflow hole for coolant pump ¡ú Item.

 

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¨C 

Remove oil dipstick tube with dipstick.

¨C 

Unbolt coolant expansion tank and lay to side (hoses remain connected).

¨C 

Remove coolant pump cover ¡ú Item.

 

 Photobucket" border="0" />

¨C 

Lever sealing cover -arrow- out of sealing flange on No. 1 cylinder end of block using extractor hook -10 - 221-.

 

 Photobucket" border="0" />

¨C 

Bolt special wrench -T10225- onto crankshaft.

  Note

It is only possible to bolt special wrench -T10225- onto crankshaft in one position.

 

 Photobucket" border="0" />

¨C 

Counterhold on special wrench -T10225-, using a suitable tool, and loosen coolant pump nut -1-.

  Note

Engines of the initial production run had insufficient clearance behind the coolant pump gear wheel to fit puller -T10221-. In this case release the gear wheel by tapping lightly on the sides of the gear wheel with a hammer and copper drift.

 

 Photobucket" border="0" />

¨C 

Fit puller -T10221- as shown and turn hexagon clockwise until the gear wheel can be removed from the pump.

 

¨C 

Unscrew coolant pump securing bolts -arrows-.

 

¨C 

Fit coolant pump puller -T10222- and turn its bolt clockwise until the puller first contacts the cylinder block as shown and subsequently pulls the coolant pump out.

 

 

 

 

 

 

 

Installing
Installation is carried out in the reverse order. When installing, note the following:
–  Moisten new O-ring with coolant. Do not use any other lubricant.
–  Fit coolant pump.
–  Tighten securing bolts for coolant pump. Torque setting: 20 Nm + 90°.
–  Install gear wheel and tighten securing nut. Torque setting: 84 Nm.
–  Install drain plugs and tighten. Torque setting: 20 Nm.
–  Lightly oil sealing lip of coolant pump cover.
–  Install coolant pump cover. Torque setting: 25 Nm.
–  Install oil dipstick tube with dipstick.
–  Fill with coolant → Chapter.

Special tools and workshop equipment required
t  Refractometer -T10007-
t  Drip tray -V.A.G 1306-
t  Torque wrench -V.A.G 1331- (5...50 Nm)
t  Spring-type clip pliers -VAS 5024-
t  Puller -T10221-
t  Puller -T10222-

   
t  Special wrench -T10225-

    

 

 



Edited by BigHerB
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gregozedobe View Drop Down
Vanorak
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Joined: 22 Dec 06
Location: Canberra, Oz
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Points: -998266 		Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jan 08 at 23:57

Originally posted by jess james jess james wrote:

newbe here,my t5 died over xmas,water in oil?,

Hello JJ, have you seen this thread ?  Might be worth trying for goodwill too  ?

http://www.brick-yard.co.uk/forum/forum_posts.asp?TID=22233& amp;PN=1&get=last#166690
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jess james View Drop Down
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Joined: 12 Jan 08
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Points: 2 		Post Options Post Options   Thanks (0) Thanks(0)   Quote jess james Quote  Post ReplyReply Direct Link To This Post Posted: 13 Jan 08 at 18:27
thanks Big HerB/gregozedobe,

i will print it out and pass to garage,hopefully he will have all these pullers etc. will let you know.


jj
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Onefut View Drop Down
Yardie
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I like pink

Joined: 14 Jan 08
Location: North Devon
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Points: 994 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Onefut Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jan 08 at 11:46
My van has been showin signs of water pump fault
im gonna try an push for VW to replace it as it is deffo a design fault
too many folk have the problem
Jess it'll be well worth you siting the above link to your garage
once VW did this repair out of warranty for one person they admitted liability
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