Mk1 1.6D jetta waterpump help - General - VWDiesel.net The IDI, TDI, and mTDI source.

• Mk1 1.6D jetta waterpump help by zozie on 22 May, 2008 06:32
• Hi all;
  
  Been a follower but this is my first post.
  Well the waterpump gave in yesterday so I'm trying to do it on my own.
  I can get a whole new one with the housing from the dealer, or just the pump  from the jobber, Which is easier? So gar I got as far as taking the alternator off....... :oops:  Now it's raining.
  http://s287.photobucket.com/albums/ll132/zozie1982/
  Any thoughts?  I guess I have to pull the alternator bracker regardless.... My haynes manual is not very thorough on the subject so if you can give me a hint or two,,,,,,
  Thanx a lot
• #1 by zukgod1 on 22 May, 2008 07:01
• Well it's going to cost less to just change the pump but safer to replace the entire thing.
  
  Before you go buying ANYTHING from a dealer contact myke_w on this board, he has OE parts for way better than the dealer.
  
  If you are going to replace the entire assy you need to remove the alt bracket from the block, just go slow. It's not that hard and most if not all of the bolts only go one place.
  
  Replace the thermostat while your there as well.
• #2 by zukgod1 on 22 May, 2008 07:11
• BTW, looks like you could spend some TIME at a car wash under the hood.
  
  YUCK!   :cry:
• #3 by BlackTieTD on 22 May, 2008 12:39
• hi zozie,
  
  i did a quick write-up on this when i did a waterpump a little while ago. i inadvertantly took the photos down from the server, i will try to find them for you. the descriptions should help a little:
  
  

  Quote from: "BlackTieTD"

  Today I changed the waterpump. Took out the alternator and its bracket. When the 3 bracket bolts are out, there is 1 remaining bolt holding the WP. You might want to pull off the thermostat housing and thermostat to drain the coolant or it will run down the front of the block.
  
  
  Here you can see the alternator bracket. There are two bolts at the top tucked underneither the injection pump, and the one shown in the photo. All 13mm.
  
  
  This one is leaking and it could be the cause of overheating. Notice the build-up on the hose connection area of the housing.
  
  
  Disassembled and cleaned up the housing. Its cheaper to buy the pulley side of the unit and reuse the old housing. Clean up the hose connections, o-ring and gasket mating surfaces at least. I spent a while cleaning up the housing so it is similar to new in all but appearance. Its a metal casting with no moving components.
  
  
  Pulley has three 6mm allen-head bolts. New gasket and 2 new o-rings for this job.
  
  
  New v-belt, 38", and re-installed tensioned to about 2mm of deflection when the belt is depressed on the top face shown.
  
  
  I parked facing uphill and refilled the coolant through the upper rad hose, then through the rad. Squeezed the upper and lower rad hoses and worked out any bubbles from the system. I changed to a reservoirless rad, my old rad had a pinhole.

  
  
  almost useless without pics but i'm having trouble finding them at the moment... good luck with it. post if you run into problems  :mrgreen:
• #4 by BlackTieTD on 22 May, 2008 12:49
• found the pics for you. here's one more for good measure:
  
  
• #5 by zozie on 22 May, 2008 14:26
• Thanx a lot  
  Finally got it done. Just toke it our for a run and seems just fine. I ended up getting a whole new one with housing from the dealer for $99, at least it's VW. I feel better than getting just the pump for $55 from the jobber. Well it did take me from 8-16:00 with some interruptions as it rained, but next time I do it it'll take about 2 hours. WOW I'm deep into this car now.... I got it in september with 129.000 KMS from first owner. I just saw it on the street and I had to have it. It sat for 6 years tho so....
  This is what I got into it so far:
  New breaks from master cylinder all the way around......
  Rear springs, 4 wheel bearings, vacuum pump, Battery, 14" rims and tires, timing belt, front shocks and strut bearings.......
  OOOH and now a waterpump. I think I'll have this car forever.......
  Next project is to clean the rust protection off the engine.... Dunno who did it but even the engine is covered with it. So while I was at the dealer I got an oil pan and rocker cover gasket so tomorrow I'll take those off, clean them and paint them.
  It's slowly coming together
  
   
• #6 by Possum79 on 23 May, 2008 15:20
• not to jack this thread but i was at german auto parts and they have a 30mm pump with housing for pretty cheap but it says you need a new pulley. any thoughts and how much for a pulley? i can get the original 40mm pump no problem but i was thinking of its not to much more why not until i read about the pulley.
  
  
  sorry for the thread jacking.