Replacing water pump on 2.1 DJ

[Aidan]

you can remove with the pipe attached if you can undo the jubilee
the pipe behind the pulley 025 121 151 is obsolete from vw probably available from classicparts in germany otherwise used from the usual breakers
I have none left now early or late

[kevtherev]

ah the pipe behind the pulley.. that runs to No 2

sorry I thought ..

[chano]

Thanks.

I managed to loosen the top allen hey bolt on the large water pipe (top left of the pump) yesterday. I didn't remove it all
the way, thought it would come out without much trouble when i continued today. Wouldn't budge when i tried today. Impossible to remove it with allen key as insert is rounded. I can't get mole grips onto it as it's too close to the pipe. I've removed the lower allen
key bolt without too much trouble, if i hacksaw the head of the top bolt, will the large metal pipe come of with a little persuasion?

There's a srapyard here on Gran Canaria with a couple of VWs, i'll see if i can find the small water pipe there before looking further afield.

Alan

[kevtherev]

could you get the allen key welded into the socket head screw

[chano]

Possibly, but with the allen key welded into the bolt head - and assuming it loosened - you would only get about half a turn
before coming up against the pipe and needing to remove the allen key.


Alan

[axeman]

i have had this problem when removing the drive shafts, the allen heads are worn. i use a 12 pointed star bit, tap it in with a hammer, squair and firmly. put the socket adapter on it and it should go. replace the bolt once you have got it out. the outher option if you have not got a 12 pointed star bit, could you not try to tap it around with a small but sharp chisile just to looosen it? both metobs have worked for me in the past.

good luck.

neil

[chano]

Thanks, Neil.

Alan

[chano]

Having made a complete mess of the head of the bolt trying every method under the sun to loosen it, my only option
now is to saw it off. I think i can get a small hackswaw blade between the head of the bolt and the washer, and fingers crossed
it should be possible to pull the pipe off the pump.

Alan

[kevtherev]

Possibly, but with the allen key welded into the bolt head - and assuming it loosened - you would only get about half a turn
before coming up against the pipe and needing to remove the allen key.


Alan

Ah but I've used a cut key (so it's straight) welded it on . and a socket on the key.

shame your having so much trouble ... but persevere

[chano]

Finally took the hacksaw to the allen bolt on the large water pipe. I've got everything loose except the lower
allen bolt on the small water pipe, which looks like it will also need cutting off. I was hoping i could remove the pump
with the small pipe attached, but it doesn't seem possible as there is only about 5mm clearance between the pipe
and the large pulley, not enough to remove the pump from the studs. Ive removed the circlip from the short length
of hose (is there an easy way to get these off!) and cut the hose as i don't want to attempt to remove the two nuts
from the other end of the small pipe.

If i could remove the large pulley the pump with pipe attached would come off easily. Advisable or not?


Alan

[kevtherev]

If i could remove the large pulley the pump with pipe attached would come off easily. Advisable or not?


Alan

yes alan you can remove the pulley
it's tight on though, you'll need a big socket and a breaker bar.
in gear and hanbrake on

[chano]

Thanks, Kevtherev.

Cutting the pipe off near the flange (wher it is corroded) would be the easiest option, but with no new or used
pipes here on Gran Canaria, i need to remove it complete in the hope that it can be repaired.


Alan

[axeman]

i think that jk have had then remaid. if they would not post it to you i, you could get it sent to me and then i could forward it it you. i was lucky eneough to buy an nos one from a friend, he was selling it becouse he had done a scooby convershion.


let me know neil

[chano]

Removed the big pulley without too many problems and removed the pump with the pipe
attached. Had to resort to hacksawing the stubborn allen key bolt, but managed to get the
pipe off in one piece. There's a whole (about the size of a pea) near the flange and a crack
where it joins the flange.


Neil, thanks for the offer. I'll try to get this pipe repaired locally, if it's not possible, i'll let
you know. I had a look on Just Kampers site, could only see the large metal water pipe.


Alan

[kevtherev]

they cost about £25. at a VW show
dubfreeze is coming up I can get one there if you like

try a want ad for the "pipe behind the pulley" in the wanted forum
lots of breakers read it