Diagnostic Please!!!

[kevtherev]

Not quite sure what i can do now?

Rob

Take the pulley wheel off?
Undo the three bolts that hold the wheel together, and remove the belt
(It's why they are there )

Then you will see it a whole heap better

[BertieWells]

think some tool buying is in order. No way am i getting those bolts out with a single 13mm

Will attempt to get the main pully wheel off. Any idea what size socket i need off hand?

[kevtherev]

No need for that to come off

[BertieWells]

Do you think i can get the pipe off and back on again with it on? It looked pretty tight but ill give it a go.

The pipe seems to run from the pump, down, behind underneath the main pully and then reconnects to the engine. It also looks like a repair has been done on it before; although i dont think this is where the leak is comming from. I think there might be a split underneath (right under the pully). If its not that pipe then i think i will need to take the pully off as the leak is comming from somewhere behind it. ... i think

Thanks Kev !!

[T25Convert]

No need for that to come off

Kev - If its the pipe that goes under the bottom pulley and he isn't taking the water pump off, then the main pulley has to come off otherwise you can't feed the pipe out round the water pump on the early system - it has limited wiggle room!

The pipe should have a rubber section in it - this was there from new, although it does look like a bodge!

In terms of what to do next, you need to work out exactly where the water starts - if the pipe is wet and so is the bottom, then to could be that pipe, the connection to the water pump or the pump itself - remember water will simply run down from wherever the leak is.

I'd start be splitting the waterpump pulley as Kev suggested, will give you more space to see what's happening below - you could do this with a single 13mm socket/spanner.

If you want to go further in you, in terms of tools, you'd need a 13mm socket, 13mm open ended spanner, 13mm ring (optional!) big spanner for the main pulley, a good lever or two (to pry the main pulley off). You'll also need some plasters (for knuckles). If you are delving deep you may also want to remove the expansion bottles and the rear engine tin (large cross head screwdriver and 10mm socket), gives a bit more space, but the edges are sharp so may need more plasters!

Good luck!!

Cheers,

Alex

[BertieWells]

You guys make it sound so easy when i read your posts on here ... i go out to the engine bay and quickly develop a headache and scuffed knuckles (the plasters were a good shout).

What is the technique for removing the pully on the pump with a single 13mm? i can't stop it from spinning.

As for removing the main pully (does it have a name?) any idea what size spanner i need to go buy or am i better off buying some sort of speacial tool?

Thanks

Rob

[T25Convert]

Right, first thing is to get the pulley in the right place - you'd need a bolt right at the very very bottom of the pulley, so that as you try and turn it the rotation doesn't cause it to spin. If you also apply some pressure to the belt wrapped round the pulley this can also help stop it rotating.

If it doesn't want to go then get some decent release spray (not WD40 - Plusgas or similar) and spray the back of the bolts to assist.

Main pulley is your crank pulley, a correctly sized spanner, or a decent adjustable spanner would be best, although it may need a long bar and a socket depending how tight it is.

None of this is tricky if you are lucky enough to have a big tool box full of things, but it is much harder if you have to make do with limited tools!! If you don't have much experience this is a reasonably rough introduction, especially if you do end up having to take the water pump off.

Alex

[kevtherev]

No need for that to come off

Kev - If its the pipe that goes under the bottom pulley and he isn't taking the water pump off, then the main pulley has to come off otherwise you can't feed the pipe out round the water pump on the early system - it has limited wiggle room!

Ah yes early cooling system, I forgot.
I thought that pipe pushed into the pump, no bolts required, and the rubber connector allows it to bend.

[kevtherev]

... rough introduction, especially if you do end up having to take the water pump off.

Alex

Oh sweet joy, one of VW's best jokes.

[BertieWells]

Ok guys here is where i am up to...

I borrowed a friend and we managed to get both the water pump pully off and the bolt that holds on the crank pulley (thanks convert) the problem now is no hammer is going to get off the actual crank pully as it is seized on proper! Is there a technique to getting it off or is it just brute force and ignorance? I was wondering if this could work? (a friend of mine gets a staff discount at halfords)

Cheers again guys for all your help

[T25Convert]

No easy way!

It has a 'woodruff key' on the shaft - a little raised tab on the shaft to stop the pulley rotating, shown here on the left hand side of the shaft:



Trouble is this is all a tight fit, especially if its a bit rusty!

What you need to do is either get a big lever and gently prise against one side then the other to ease it off little by little by little (using wood packers so you don't destroy anything!) or get a puller.

The puller you link too may be too big to get into the space - you'd need a very flat puller - this one is made for this job (and this job only!!) http://www.machine7.com/product.php?xProd=11983 - you may find something similar at your local Halfords / automotive parts centre, you may not.

I'd try getting a big bar in there and levering gently first...

Good luck,

Alex

[BertieWells]

Ok so iv been using the spanner hammer technique and after about 20 mins iv got it out 5mm. Im worried im pulling out more than just the crank pulley though. Have a look.

[kevtherev]

thats fine.
impossible to pull anything else out

[BertieWells]

Ill hold you to it back i go ...

[CovKid]

The pump itself can seep water as it runs past pensionable age. Can you feel any play in waterpump pulley? Had the odd screeching noise when first starting up? If no to both, probably o-ring seal where pipe goes into pump. Keep at it - you'll find it.