Waterpump won't come out... - Troubleshooting - VWDiesel.net The IDI, TDI, and mTDI source.

• Waterpump won't come out... by Trimster on 08 Sep, 2007 17:30
• Argh.... I've got every visible bolt out and the waterpump just won't come out. The issue is the Air cond. bracket. The waterpump housing is made in such a way that it goes in behind and between the air cond. bracket and the block. I have removed every bolt visible. Every one! I am trying NOT to take off the fuel pump.
  
  I can actually move the pump but it seems to pivot on something behind the fuel pump. It there some kind of thru-sleeve that would span one of the bolt holes so a wrench-hand would not over tighten and break the waterpump casting?  I'd love a real drawing of how this baby mounts up.
  
  Any help would be appreciated. Things are not going well on this end.
  
  bob
  
  Update:  Found the bolt that's mucking up the works. It is actually un-reachable without removing the fuel pump. Who designed this idea? It would have been a no-brainer to cast a notch in the bracket to get a socket and extension in there..... I think I'm going to hate this job.
• #1 by Trimster on 08 Sep, 2007 18:21
• ...so my plan is to :
  -mark the timing belt and cam and fuel pump pulleys
  - pull the fuel pump pulley
  - disconnect the injector lines
  - un-mount the fuel pump from the front bracket so I can raise it up enough to get a socket into the last bolt.
  
  Any problems or short cuts anyone can see?
  
  thanks
  
  bob
• #2 by subsonic on 08 Sep, 2007 19:23
• Make your own notch?  Small keyhole saw at slow speed? Small grinder?
• #3 by Trimster on 08 Sep, 2007 19:31
• What are the important areas to notch/mark?  I am assuming that the fuel pump pulley needs a pulley puller to get off and does NOT have an alignment pin... am I right on that? So I notch the tip of the pump shaft bolt and the pulley inner hub area?
  
  Seems that there is only one bolt that holds the innermost(towards the engine center)  bracket on the back side of the fuel pump.  I'm calling the pulley side the 'front' of the pump in this case.  The manual I have does not have a word on Diesel pumps so I am flying blind here.
• #4 by Trimster on 08 Sep, 2007 20:26
• Not sure what you mean by an 'S' wrench but I used an offset wrench to get one bugger off. I think the bracket that holds just the Alt is way different from the one that holds AC and the alt.
  
  Bob
• #5 by burn_your_money on 13 Sep, 2007 12:04
• If you do end up pulling the pump the way you described sounds right. There are a total of 4 bolts holding it in place, 3 on one end, 1 on the other end. Mark the pumps position on the bracket that it mounts to. You will want to bring it to a shop and have them set it properly though, or pick up a set of gauges for around $50 shipped and do it yourself
  
  Have you tried a 1/4 inch swivel with a 1/4 extension?
• #6 by addautomotive on 14 Sep, 2007 10:19
• stupid question: Why not unbolt the pump "face" 9 x 10mm bolts?
  
  Do the timing belt while yer in there. Takes 3-4 hours and is always way easier.
• #7 by Trimster on 14 Sep, 2007 10:36
• Not sure how to get 2 of the bolts that are behind the lower belt shroud. that shroud looks like more un-fun work and would involve pulling the lower pully off. working space sucks... like every other area on this project.
  
  bob
• #8 by addautomotive on 14 Sep, 2007 10:46
• I had to do my water pump TWICE, because the FLAPS "rebuilt" pump failed after 600kms/3 weeks.
  
  I find it pretty easy to do it from the timing belt side.
  
  -remove belts & lower pulley
  -remove timing belt covers
  -remove timing belt
  
  Water pump is helt on by 9 x 10mm bolts
• #9 by Trimster on 15 Sep, 2007 20:23
• OK, it's done. I'm glad my life did not depend on it.
  
  If you car has air conditioning, the easiest way IS to pull the belts, timing belt covers and pull the front of the pump off.
  
  The bracket that hold the whole mess together IS different than the non-air models so the 'S' wrench and the 1/4" drive sockets just won't fit... on mine anyway.
  
  So on to the next task... if you own a Caddy, there is alway something.
• #10 by jtanguay on 15 Sep, 2007 20:44
• Quote from: "Trimster"

  OK, it's done. I'm glad my life did not depend on it.
  
  If you car has air conditioning, the easiest way IS to pull the belts, timing belt covers and pull the front of the pump off.
  
  The bracket that hold the whole mess together IS different than the non-air models so the 'S' wrench and the 1/4" drive sockets just won't fit... on mine anyway.
  
  So on to the next task... if you own a Caddy, there is alway something.

  
  
  look on the bright side... no payments.. just car repairments  :lol: "why don't you buy a new car?" I hate when people say that... car payments.. insurance.. oh no reason!  :roll:  </tangent>  :lol:
• #11 by insdtanoodles on 25 Sep, 2007 16:42
• Quote from: "jtanguay"

  Quote from: "Trimster"

  OK, it's done. I'm glad my life did not depend on it.
  
  If you car has air conditioning, the easiest way IS to pull the belts, timing belt covers and pull the front of the pump off.
  
  The bracket that hold the whole mess together IS different than the non-air models so the 'S' wrench and the 1/4" drive sockets just won't fit... on mine anyway.
  
  So on to the next task... if you own a Caddy, there is alway something.

  
  
  look on the bright side... no payments.. just car repairments  :lol: "why don't you buy a new car?" I hate when people say that... car payments.. insurance.. oh no reason!  :roll:  </tangent>  :lol:

  
  
  I get the same thing all the time, it just looks like I will end up replacing every part before the car runs nice, then it will start all over again.