DIY: VR6 water pump

[schoona]

First up, I need to point out that I didn't have a cmaera handy and just wanted to get the job done anyway, so I have no pictures. I will endeavour to describe my method, if it can be improved upon, by all means advise

Tools required (from what I can recall):
-socket set
-screwdriver set
-allen keys
-packing
-hydraulic jack
-multi-grips
-bucket/container
-new water pump
-torch
-grease

Procedure:
1. Jack the car up. Jack it up close to the jacking points but leave enough room to put jack stands at the jacking points specified (along the side sill). I used block of timber underneath the chassis.

2. Drain coolant. Unscrew the cap of the expansion tank. Underneath the intake manifold is the "crack pipe". Towards the driver's side on the underside is a plug. Use a flat balde screwdriver to undo this. Have bucket ready to catch. On the passengers side at the bottom of the front bar (just behind) is the bottom hose ofr the radiator. Grip the spring clamp with multi-grips and pull hose off. Again catch coolant. It's pretty tough to get the hose off, i wore quite a bit of it

3. Remove air box and piping up to the throttle body.

4. In the centre of the front bar, underneath the car, is a "cover" with a hex bolt (10mm) in it. Take the cover off with a ratchet, then unscrew the hex bolt. The bottom half of the engine mount will drop. Put in safe place.

5. Almost directly underneath the throttle body is the right rear engine mount. Using a phillips head screw driver, unscrew the bracket mounting the air con lines to the fire wall and unclip them from their seats. Then use a socket on an extension bar to reach down (use a torch to see) and unscrew th 2 bolts (either side of mount). Store them.

6. Near the gearbox on the passengers side is the other rear engine mount. Use a socket to loosen the bolt that is on the inside. The outside one I found too difficult to access.

7. Use the hydraulic jack and a small block of wood (about the ewidth of the sump) to jack the engine up from the sump. Have a spotter/check to see when your water pump pulley clears the shelf where your airbox sits.

8. Removal of pump. This can be done two ways:
A: use an allen key to crack the bolts holding the pulley to the pump. I could'nt (used penetrene, WD-40, shocking with light tapping with a hammer, hammer on allen key, tighten then loosen) so went with method B. After you loosen those allen key bolts, take the tension off the accesory belt, remove tensioner (for clearance (idler pulley)).

B: Spin the pulley to the correct position to allow you to take the allen key bolts out that fasten the pump to the block. It's quite tight, so use a screwdriver/ pry bar etc to try and lever the pulley/pump assembly out of the housing. BE CAREFUL!

Slide pump out. Clean area from grit/dirt with cloth/emery paper.

9. Grease the o-ring on the new pump, and the surface that mates to the block (lightly). Slide it in. Reverse of removal of pulley/pump to install. I used a torque wrench (150 inch ounds) to get "equal" tension and get the pulley sitting square. Not sure how imperative this is though...

10. Put tensioner back on, make sure belt is correct (sequence/seating etc).

11. DRop block back onto mounts. Tighten mounts etc...

12. Re-assemble intake assembly.

13. Refit crack pipe plug/radiator hose. Lightly grease the radiator fitting/hose. Makes it slide in so much easier.

FILL WITH COOLANT.



Hope this helps guys

Note: Mine was leaking. Have 194 xxx on the odometer.

[schoona]

Thanks to Matt for supplying my pump also. Was on my front door in 2 working days at a very good price

[chris.]

good stuff man


might want to remember to becareful when jacking on the sump too

[Spyda]

Sticky??!!

[schoona]

good stuff man


might want to remember to becareful when jacking on the sump too

Certainly be careful. Just keep an eye out

[Golf Houso]

Was the actual pump faulty or was it just the gasket? I got a friend of mine to change the one on my VR6, when it had 73k. The pump (plastic) although fine was working, just the gasket was completely gone, I replaced it with a new metal one from ASV for $95 for reference.

[schoona]

Was the actual pump faulty or was it just the gasket? I got a friend of mine to change the one on my VR6, when it had 73k. The pump (plastic) although fine was working, just the gasket was completely gone, I replaced it with a new metal one from ASV for $95 for reference.

Was only a busted o-ring Branko, but seeing as it was going to come out, i played safe in case there were any other problems.

[Golf Loon]

Yup, as if youd do all that job and just change the o ring.

Glad it worked out Mal, nice write up.

[Golf Houso]

Yup, as if youd do all that job and just change the o ring.

Glad it worked out Mal, nice write up.

I'd done all the coolant hoses before that, so yeah I basically had to, not that I did it though...

[Tubbs76]

Do you need to left the motor to do this? To anyines knowledge, any way to do so without lifting off mounts?