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Water pump stuck! PLEASE HELP!!

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Vanorak
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    Posted: 13 Jan 19 at 23:21

Well done P38IRL thumbs That was a bad one! I have only done a few 2.5 water pumps but I have always used my own basic tool (plus a good long bar). I had heard that the proper tool can break. When I retired I was asked several times if I wanted to part with my old home made tool which I had always leant to anyone that needed it. But I'm keeping it for as long as I have the van. I'm guessing that your problem is not unknown. 

If anyone wants to make one it's an old BMC engine hook thinned down a bit by the hole so that the nut on the pump shaft fits with the max amount of thread possible. The pump nut needs to be reversed so that the captive washer doesn't obstruct the tool. It ends up with 3/4 worth of the nut thread used which is enough to pull out the pump without stripping. The tool is stiffened up by a couple of welded corners. 

This gives you something solid with which to lever out the pump with a 4 foot bar and a block of wood to protect the gearbox. If you have the luxury of having the engine on the deck like P38IRL I'd go for a big slide hammer on it before getting really serious with grinding tools or heat. But whatever works for you is good. Smile 

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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 13 Jan 19 at 19:16
Well to say i had problems getting this pump out is an understatement. I spent 2 weeks and I almost threw in the towel, i spent days heating cooling trying to pull it out when eventually the shaft from the pump came out and i was left with just the race which i couldt cut. I ended up today welding a towing eye in to the race and using a highlift jack on the engine in an attempt to remove the pump. still no joy but under massive load i began to hit the eye with a hammer and the race began coming out with every strike. after removing the race i then cut through to the 2 10mm holes i drilled close to the wall of the pump housing and had to beat and break the pump out bit by bit. it was a horrible job and i really thought it had beaten me. 

after i removed the old pump i cleaned the rust from the inside of the pump housing using a die grinder and offered up the new pump and it seems to fit well. As the engine is out i will be doing a few small jobs and hope to have the engine in by next weekend








Look at the bend under load










All done
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 18:56
Be careful not to damage where either of the seals sits and be sure no bits or swarf can fall inside! Before you start drilling or heating it might be worth bolting something under the nut and using a giant lever (4 or 5 feet long and not bendy) against a block of wood on the gearbox as I mentioned.  Always works if the bar is big enough. LOL   
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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 17:48
yeah if it doesent work i will drill in behind the casing to the eye of the pump and hit with a drift to see if i can get it moving 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 17:40
Maybe if your luck's in..  I once had an old 6 cyl Jag engine suspended overnight to get a cylinder head seized on its studs off and it never moved!  Good luck though. Smile   
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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 17:32
the damaged part is only to hold the bolt for the tool, normally there is a plastic clip that holds a cable in place. not too worried. but you see the amount of force that has been applied to make that aluminium collapse like that. it mad. 

engine is now suspended from the water pump and been dowsed in penetrating fluid. i will leave it over night and see if i can get it to start loosening this way first. 





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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 17:18
Oh good! Now you've got all that room, if you can get a big slide hammer and make up something to fit it to the pump shaft it should come out ok.  You will have to see if that damage to the gearbox casting is important or not.  Is it one of the bolt holes for the tin plate?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 16:21
No buddy they are out.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 16:01
In the second pic it looks like the top bolt is still in the pump! Shocked  



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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan 19 at 00:43
well i bit the bullet and dropped the engine this evening. 





[/QUOTE]

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Post Options Post Options   Thanks (0) Thanks(0)   Quote zedzedeleven Quote  Post ReplyReply Direct Link To This Post Posted: 17 Dec 18 at 10:26
That official tool looks like it is made out of poor quality alloy.
1.9 85ps swb 2004 in friesan green.

bring me sunshine.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 16 Dec 18 at 22:13
Yes, just remove the gear and then take the pump bolts out. I haven't got the official tool but I made my own up. Mine fits under the central nut for the gear and then you use a big bar. (a really big bar!) The pumps can be very tight. I use a four foot lever with a block of wood as a fulcrum (and to avoid marking the gearbox) which levers the pump out. It ain't pretty but it works!

Edited by T5 TDI - 16 Dec 18 at 22:34
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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 16 Dec 18 at 09:02
Sorry I see predictive text added in the name "Karen" 😂😂😂
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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 16 Dec 18 at 09:01
Thanks Karen for getting back to me. I am in the fortune position that I have a decent workshop with a lift so if it comes to it I will take the engine out mysslf. BUT I've never taken an engine out before so that would make it interesting.

Last question, the pump is not locked in by the engine in any way? I see the instructions to manually crank the engine but that's only to get the cog off the pump right? After that remove the 2 bolts and the pump should pull out?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mikeekim Quote  Post ReplyReply Direct Link To This Post Posted: 15 Dec 18 at 18:14
Hello p38irl,

Afraid sounds similar to me, the removal tool broken and the water pump wouldn’t budge because it had part corroded and seized onto the engine block.

It was some years ago now and I no longer have this van. From memory the vw garage I took it to ended up removing the engine soaking the pump in penetrating oil and suspending the engine from it until it eventually came free. Wasn’t cheap afraid.

Hope yours come free easier, fingers crossed ther must be a better solution!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote P38irl Quote  Post ReplyReply Direct Link To This Post Posted: 15 Dec 18 at 16:06
Hi, any update to this stuck water pump? I'm in exactly the same boat. Even cracked the removal tool. Doest seem to want to budge.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Alonline Quote  Post ReplyReply Direct Link To This Post Posted: 07 Sep 13 at 00:44
 
VW Goodwill? never seen sight nor sound of thisConfused
My experience is, you bought it Mug! You want what!LOL
 
You can ask but that lighting bolt/pot of gold has never landed near us and all the wagons have a full VW dealer service history.
 
Its a battle to get them to fix the door that fell off a 2 week old wagon, fix the bad paint work once, and now going back again to get the paint work fixed again, (all paint work done at VW approved paint shop, tossers Agnews)
 
Sorry meds wearing off.
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 05 Sep 13 at 00:30
No problems Mike.  

If your van has been regularly serviced by an official VW dealer it might be worth asking them to approach VW for a "goodwill" contribution to fixing this, as it should be relatively straight forward job to replace a water pump.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mikeekim Quote  Post ReplyReply Direct Link To This Post Posted: 04 Sep 13 at 19:23
Hello Greg, straight after I posted that response to you I put two and two together and notice your username coming up in so many of the posts relating to this and many other tech problems on here.  Excuse my ignorance.

There is still no light at the end of the tunnel with getting this pump out.  I forwarded this thread to the mechanics at the garage for them to look at and they still cannot remove the pump.

They are planning on dropping the engine to get better access.

This is becoming a nightmare!!
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 04 Sep 13 at 17:40
Originally posted by mikeekim mikeekim wrote:

Gregozdobe I meant the common problem with the waterpump needing to be repaced on the T5.  There is lots of information on this if you search google.  There is also lots of threads about it on this forum, see this link:
 

Because you said:
Quote  Does anyone know of any other method to remove such a heavily corroded pump?
Has anyone else suffered this problem? 
I thought you were referring to the difficulty you were having removing the water pump on your van.  I'm very aware that water pump failure is an all-too-common problem with VW's R5 motors.  

In fact I've contributed to many of the threads on here about it, including the different treatment that T5 owners received compared with Touareg owners.  All Touaregs got an out-of-warranty free replacement campaign, while T5 owners mostly had to pay themselves unless their dealer was very, very nice and argued with VW head office on their behalf.
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