Quick Coolant Question

[BertieWells]

Hi guys, i haven't had much time to check as i have to run (litterally) off to work. I thought id see if you guys can figure it out while im away

I have a leak. Not in any obvious pipe. Seems to be comming from around/under water pump (might be wrong).
Im in the process of removing the water pump? Any thing i should watch out for or prepare for while im doing this?
I hear the thermostat housing is pretty difficult to get off?

So is there anything springing to mind as to where the leak might be comming from?

Regards

Rob

[CJH]

Any thing i should watch out for or prepare for while im doing this?
I hear the thermostat housing is pretty difficult to get off?

Early cooling system layout (thermostat by the water pump)? Plenty to worry about I'm afraid.

https://club8090.co.uk/wiki/Co ... overhaul_3" onclick="window.open(this.href);return false;

[BertieWells]

Yup, haha thanks I have a new thermostat comming with some replacement pipes so it was going to have to come out eventually anyway

Ta

[California Dreamin]

The water pump itself has a breather hole between the bearings underneath. When the seal/bearing fail they leak out of this hole.

Martin

[BertieWells]

Hi martin, there is a little play in the pulley wheel on the water pump so i assume the barings have gone. Can they be replaced? If not has anyone tried the water pumps from euro car parts?

[CovKid]

No you can't replace the bearings. The whole thing wears. Slight water loss and play at the pump are symptomatic of imminent failure. I wrote the WIKI on the 1.9 DG pump change and if you're noticing play in the pump, you need to approach the job as I have suggested and treat it as an overhaul. The waterpump is the engines heart. I used the one supplied by GSF and have had no probs but if you're in any doubt get the Brickwerks one.

You'll just have to roll up your sleeves I'm afraid. I've included all the potential pitfalls and how to deal with them. This isn't a job you'll be keen to revisit. However, take your time and do it well and the pump will give many years of service.

[pionte]

The write up that covkid has done is fantastic, he has not over exaggerated how much of a pain this job is... I hadn't read his write up when I did mine, I naively thought it would be a couple of hours.... I ended up removing the engine to complete the task!
My water pump and thermostat housing had become one..
I tracked down a serviceable used thermostat housing, but we warned that they are seriously rare ( I know have another spare... Just in case )
Good luck... Once it's done it will be good for years to come.
As covkid said, you won't want to do this job again, so don't be tempted to save a tenner on cheaper parts, buy from brickwerks.. In my opinion it's not worth the risk.

[BertieWells]

Thanks guys ill follow your guide as well as i can

Anybody have any experience with EuroCar Parts??

Aslo im 90% sure i have the earlier cooling system and so need the early pump. How can i confirm this?

[T25Convert]

Well early looks like this:

http://www.coolairvw.co.uk/Item/Shop_by ... _Pump.html" onclick="window.open(this.href);return false;

and late like this:

http://www.coolairvw.co.uk/Item/Shop_by ... t-CB-.html" onclick="window.open(this.href);return false;

I believe from previous comments you have the early system - just checked, you do as there is the pipe that comes straight out the top in previous post.

Eurocarparts are okay, quality variable, but price often good! If you do go, order online as parts are cheaper through 'click and collect' than they are in store (still not worked out how that works).

As said above its a pig of a job. Mine leaked after an engine rebuild, and even though every nut and bolt was easy to undo it was still a pig! Everything clashed with everything, and before you know it you've taken off most of the back of the engine ancillaries.

Post up as you can go and we can offer sympathy/advice as required!!

Good luck,

Alex

[BertieWells]

Ok cool thanks. I have to say euro car parts have the worst customer experiance i have had to deal with (wrexham branch). The pump i need is out of stock so i ring up to ask when it will be avalible. After being left in silence for 5 minutes with no reason why he came back and said "can i ring you back in 2 minutes we might be able to get you one later on today". After half an hour i ring back up, another guy answers who is really appologetic and says he will ring me back in 5... guess what. Think i will order from brickwreks as they definitly come with all the gaskets etc.

Im naievely looking forward to getting stuck into this got the pulleys and pipes off for now. Will report back when i venture out to do more

Also im not convinced my temp sender is working, is this the one i need?

http://www.brickwerks.co.uk/index.php/t ... -2005.html" onclick="window.open(this.href);return false;

[BertieWells]

Ok so pipes just arrived ... way too shiney

IMG_20141021_140012.jpg

Ok here is what im up to.
I loosened the 2 bolts on the thermostat housing (just)
I have removed the nuts holding the water pump to the engine

What i cant do is remove 2 of the pipes:
the bottom pipe leaving the coolant expansion tank i cannot remove from the pump (1)
and the short little stubby at the back of the pump (2)

IMG_20141021_131626.jpg

The rest of the pipes are off.

Any tips ??

[T25Convert]

The one from the expansion tank - man up!! Release the clip, and slide it up the pipe well out the way. Now wiggle/twist the pipe until it slide off. If its really stuck with accumulated crud then getting something blunt under the pipe can help, but you do run the risk of punching a hole in it if you're not careful. Alternatively take it off the expansion bottle end and remove it from the pump when its out the van.

The stubby one is a cruel joke, invented by a sadistic German gentlemen... You will need to release the spring clip and put it as close to the other one as possible (but there is not much room). Then, as you remove the pump the pipe should pull off, but is a pain as often you also need to release the spring clip again as it may still be clamping the pipe to the metal stub inside. Just wait, its almost even more fun getting it back on again!!

You might want to consider ordering one with your water pump, this way you can:

a) cut the old one off

b) not have to worry that one day you may need to change it!

Cheers,

Alex

[BertieWells]

Ok so i did the manning up and i have removed everything

Loosened the thermostat housing from the pump first then removed them all as a lump. Separated thermostat housing from pump then had the trickiest job of removing the 2 smaller bolts that allow you to get at the thermostat. Pulled the thermostat out and it looked like this:

IMG_20141022_114149.jpg

Not sure how that was possible but would explain why my thermostat was stuck open

Thanks for your help guys ill let you know what i get stuck with when it comes to putting it back together

[BertieWells]

Ok so we're all back together and looking shiney (in places). The problem im having is filling it back up.
Two pipes going over the back of the engine to the radiator. The bottom one is hot but the top one has a big air pocket. The top pipe is hot near the engine but cools down as it goes higher (so air pocket?) The bleed screw on the pipe dosent seem to fix this. The radiator bleeds out with no air what so ever. And the fans come on hot in the cab. Im confused and tierd ... anybody have any suggestions?

Rob

[CovKid]

Chances are, you're not getting the engine revs high enough to expel the air. Plonk a brick on the accelerator pedal and get that air out. Sometimes it'll work its way out overnight too.