Water pump stuck! PLEASE HELP!! |
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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 13 Jan 19 at 23:21 |
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Well done P38IRL 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. |
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2004 2.5 174
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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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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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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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.
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2004 2.5 174
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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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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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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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.
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2004 2.5 174
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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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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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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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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2004 2.5 174
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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No buddy they are out.
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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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In the second pic it looks like the top bolt is still in the pump!
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2004 2.5 174
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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well i bit the bullet and dropped the engine this evening.
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zedzedeleven
Vanorak Joined: 05 Jan 06 Location: west cumbria Status: Offline Points: 1169 |
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That official tool looks like it is made out of poor quality alloy.
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1.9 85ps swb 2004 in friesan green.
bring me sunshine. |
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T5 TDI
Vanorak Joined: 05 Nov 05 Status: Offline Points: 3687 |
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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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2004 2.5 174
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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Sorry I see predictive text added in the name "Karen" 😂😂😂
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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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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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mikeekim
Newbie Joined: 03 Sep 13 Status: Offline Points: 8 |
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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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P38irl
Not Quite Newbie Joined: 15 Dec 18 Location: Ireland Status: Offline Points: 16 |
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Alonline
Vanorak VW Customer Service Joined: 18 Apr 10 Location: Belfast Status: Offline Points: 2517 |
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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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gregozedobe
Vanorak Joined: 22 Dec 06 Location: Canberra, Oz Status: Offline Points: -998266 |
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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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mikeekim
Newbie Joined: 03 Sep 13 Status: Offline Points: 8 |
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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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gregozedobe
Vanorak Joined: 22 Dec 06 Location: Canberra, Oz Status: Offline Points: -998266 |
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Because you said:
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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