Water pump replacement

[WPKenny]

Hi everyone,

Yesterday I purchased a 1985 VW T25 1.9 petrol campervan. I went all the way up to Stockton on Tees to collect it with my wife. We hired a car so we could leave it up there and drive back together rather than her following me in our car.
We were about 120 miles from home (Dover) when we hit a little bit of traffic on the M1 and I noticed clouds of white smoke coming out of the back of the vehicle.
I pulled over and a free recovery vehicle took us to the nearest service station where we made the decision to sign up to the AA.
They came out and he told us it was the water pump that was gone. He demonstrated this by getting me to start up briefly and I could see water flying out around the spindle and all over the engine.

So after getting towed home and getting back at 5:30am with a FAR lighter wallet I have ordered a Haynes manual and got online to research what water pump I might need.

I have found posts that have help me identify the engine as a DG but what I have picked up on is that not all water pumps were created equal.

I'd like to ask if anyone is able to help me pick out the correct water pump and if anyone has any "gotchas" or general tips to supplement the haynes manual that's on it's way to me?

I can provide pictures of any parts as long as I can get my camera to it.

Thanks in advance.

[Ian Hulley]

At 1985 you could have either the early or late cooling system. If you have a plastic thermostat housing at the gearbox end of the engine it's a late system

Early ... http://www.brickwerks.co.uk/shop?page=s ... ory_id=118
Late ... http://www.brickwerks.co.uk/shop?page=s ... ory_id=118

Welcome to the Forum

Ian

[WPKenny]

Hi Ian,

Thanks for the amazing quick response. I've got a picture of the overall engine. I *think * it looks like the later one but I'm afraid I have zero mechanical knowledge.

I've attached a picture of the engine if you're able to cast an experienced eye over it?

T25DGEngine_resized.jpg

[kevtherev]

nope.. that's an early one.. tough luck

[WPKenny]

nope.. that's an early one.. tough luck

Oh. Why's it "tough luck"? They're tougher to replace?

[Ian Hulley]

Much of the early system is now obsolete ... the alloy thermostat housing being one of the parts, so be very careful udoing and retightening the components.

Ian

[WPKenny]

Much of the early system is now obsolete ... the alloy thermostat housing being one of the parts, so be very careful udoing and retightening the components.

Ian

Ah.

That doesn't sound so good. I'll be sure to use caution.

I'm going to go ahead and order the early model water pump and eagerly await the arrival of it and the hayne's manual!

Thanks again for all the help.

[WPKenny]

Well, procrastination is the word of the day so far. I finally got round to buying most (all?) of the tools I need for the job and made a start. My first hurdle was stopping the wheel on the water pump turning as I tried to remove the bolts. Luckily my neighbour turned up and happened to have a second ratchet with the right sized socket which made removing the bolts a doddle. Then It looks like it was going to rain so I decided to leave draining the coolant to another day.

I decided to tinker with a few other bits. The stereo only plays out of the left hand speaker so I took the door panel off and checked out the right hand speaker to find that one of the clips holding the cable on was in bad shape. Trying to bend it with pliers just made is disintegrate so I trimmed the end and touched it to the speaker terminal but it still wouldn't produce a noise. The left speaker is terrible anyway so I guess I'll be replacing the cabling and both speakers when I get a chance.

Then I took a look at the windscreen washers. I can hear the motor going but no water comes out. So I fill up the washer reservoir and it all seems to be falling out the bottom of the van. The Haynes manual shows that there's a spout that goes into the reservoir so I though maybe that had gotten misaligned since there was a screw missing from the bottom of the reservoir. Attempting to remove the remaining two bolts, I found one came out fine but the other would rather turn with the bolt the other side than come undone.

So rather than spend any more time tinkering I locked up and went to pick up the wife.

Hopefully tomorrow will be a bit more productive!

[WPKenny]

I think I might have to admit defeat

I made a proper start tonight on swapping the water pump. I drained the coolant and sized up my tools. Last night I had gone round all the bolts and been fairly liberal with the wd40 so was hoping it would be nice and straight forward.

Nope.

The first bolt sheared off after just a few turns!
'Not the end of the world' I thought. 'Just get the rest of the bolts out and worry about it later.' The next bolt, the long one attaching the thermostat to the pump came out fine. Brilliant! So I move to the next one but it won't budge. Wd40 comes out and I select my 6mm hex key to try some other bolts.some straining and then no resistance. Yup, I'd sheared off the inside teeth of the hex bolt. Argh!
So I move back to the other bolt I'd left some more wd40 on but try as I might, it's stuck fast. Any more effort and I risk shearing the bolt or rounding off the top.

And now I'm thinking it's time to get someone who knows what they're doing before I cause more damage.
Does anyone know of any reputable garages in the Dover area of Kent?

[jrt]

Welcome to waterpump hell, glad you could join me! To free any studs/bolts use plusgas not wd40 as it penetrates better. I also sheared of the bolts in my thermostat housing but have had them drilled out, if you search on here there's a post with the details of someone who can refurb the housing and clear out any bolts[mm?] I also had a knackered hex head but got it off with loads of lubrication and a small pair of mole grips done up mega tight.
Good luck with the rest if you do continue
David

[kevtherev]

Yes WD40 is a water dispersant..

heat removes old bolts better than any spray I have found...that and the patience of jove

[WPKenny]

Ok I'm definitely throwing in the towel now. Despite a couple of days applying tons of penetrating oil, I've broken the top off another bolt.
I've emailed a mobile mechanic for a quote.

[Cruz]

I also sheared of the bolts in my thermostat housing but have had them drilled out, if you search on here there's a post with the details of someone who can refurb the housing and clear out any bolts[mm?] David

https://club8090.co.uk/forum/viewtopic.p ... at+housing" onclick="window.open(this.href);return false;

Metalmick8y will be busy He fixed my spare thermostat housing that I picked up for £10

I know 2nd hand coolant pipes are not as good as getting new ones but due to the obsoleteness and rocking horse "pooh" of everything early cooling system related I have gathered spares for every rubber hose and metal pipe as well as a rainy day early thermostat housing. It's the only way to gaurantee that when IT happens I am only off the road for a minimum period. Recently had a new water pump fitted so that's one more I don't have to worry about. I got it done at Gasure rather than snap every bolt myself (plus I'm lazy)

Other than the thermostat housing the other 'like rocking horse poo' part is the metal water pipe that runs over the top of the engine between the carb and the crankcase breather tower/alternator. 025-121-081D

Picture CLICK HERE

Doesn't help you, but it's food for thought

E D I T: Also a few early pipes available from http://www.brickwerks.co.uk/shop?page=s ... ory_id=118" onclick="window.open(this.href);return false;

[jrt]

Hello, i was wondering if your pump pulley was changed when you had your pump replaced? After a fortnight struggle with snapped bolts, siezed studs etc i finally fitted my new pump yesterday morning. When i ordered it i asked why i may have to change the one piece pulley for a two piece, after going off to ask someone i was told because it may be worn, i said it looked alright and so wouldnt bother. Low and behold yesterday morning i find that my pulley doesn't line up properley. I telephoned vw heritage to order a two piece pulley and was told they don't have them in stock- they order them in from Germany-because they don't sell enough of them. He said he'd never heard of changing a one piece pulley for a two piece. Ordered one from jk for Friday.
David

[WPKenny]

Had a mobile mechanic pop over today and said it should only take a couple of hours to get the pimp off, tap out the knackered screws and out it all back together. With a bit of luck it should be roadworthy by this time tomorrow!