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VR6 [Archived] 2.8l 12v VR6 Engine Forum DIY - Replacing the main water pump on a MKIV 12v
VgRt6 Moderator DIY - Replacing the main water pump on a MKIV 12v VR6 « » 11:41 AM 12-1 6-2003
I had some free time and all the necessary pics, so I put this little DIY together. Hope it's useful to someone.
Offline Member Since 3-7-2002 15876 posts Germantown MD 99.5 Jetta GLS VR6
REPLACING THE MAIN WATER PUMP ON A MKIV 12v VR6 The following outlines the procedure for replacing the main water pump on a MKIV 12v VR6 engine. It is common on high-mileage VR6 engines for the bearing in the pump to fail, resulting in a loud grinding/scratching noise when the engine is running and eventually, a significant coolant leak (the bearing acts as a seal in the pump). Contrary to what the Bentley Manual says, the engine must be raised slightly to replace the pump (it actually neglects to mention anything about having to raise the engine ). The steps below will describe how to prep the engine for raising, how to raise the engine and how to remove/replace the water pump. The procedure below was based on a '99.5 MKIV Jetta GLS 12v VR6 and should be valid for all MKIV 12v VR6 cars regardless of model and year. The steps for raising the engine to access the water pump will be slightly different on other 12v VR6 cars (MKIII, Corrado, custom swaps), however the steps for actually removing and replacing the water pump should be the same. The procedure may also differ slightly on the MKIV 24v VR6 engine, although the steps below should also be very helpful for replacing the main water pump on that engine. Please do these procedures at your own risk and be ready to make small adjustments while doing them. Also, please be observant while removing parts so that they go back together correctly. The procedure below is fairly involved and potentially dangerous and extreme care should be taken while performing it. Depending on how mechanically inclined you are, it should take somewhere between 2 and 4 hours to perform. We had little idea about what to do when we started this procedure (other than researching the procedure for a MKIII 12v VR6) and it took us 4.5 hours to perform, including a lunch and beer break. I purchased a replacement water pump (VW# 021-121-004-A) at I m p e x for $48.50 (recently raised to $56). The unit is manufactured by Hepu, has a metal impeller (significantly better than the plastic impeller which is used on some versions of the water pump) and comes with a new o-ring. There is also a Graf version available for roughly the same price. I'm not sure what material the impeller is made of on the Graf unit. Just in case my water pump pulley was damaged from running the engine with a water pump with a bad bearing, I purchased a new pulley (VW# 021-121-031-A) from Impex for $12. I reused the existing bolts when I performed the below procedure. If you want to purchase new bolts (not a bad idea since they sometimes strip when being removed), the VW part#s are N905-442-01 for the pulley bolts (need 3) and N-902-218-03 for the pump mounting bolts (also need 3). They can be purchased at Impex for $0.62 and $0.95 each, respectively. For those who want to replace engine/tranny mount bolts that are removed (some are stretch bolts), the part#s are as follows: - passenger's side engine mount-to-body bolts - VW# N-905-969-02 (need 2) - pendulum mount-to-tranny bolt, front - VW# N-102-466-03 (need 1) - pendulum mount-to-tranny bolt, rear - VW# N-905-970-01 (need 1) - driver's side mount-to-tranny bolts - VW# N-102-096-03 (need 2) The tools/parts needed to perform the procedures are: 1) two jacks (can probably be done with one, but is easier with two - the procedure in this DIY assumes two jacks will be used) 2) two pieces of wood - I recommend a one foot long piece of 2x6 (only one piece of wood is needed if only one jack is used) 3) small flathead screwdriver (to help undo hose clips and harness connectors) 4) large flathead screwdriver or small pry bar 5) T25 and T30 Torx sockets or drivers 6) medium Phillips screwdriver 7) socket wrench with 10mm, 13mm, 16mm and 18mm sockets 8) 6mm hex socket or wrench 9) long socket extension - 6" or so is fine 10) M8x**x1.25 pitch bolt, where ** is the length in mm (available at Home Depot, Lowe's or other hardware stores). I have not specified a length since it varies depending on the model-year car you have. Special thanks go to Eric (BCDS2003T), James (James 93SLC) and Shashi (DJ-SBK) for their help with the procedure.
Let me know if you have any questions. As always, do this procedure at your own risk. I am not responsible for any mistakes in the below procedure or those that you make while performing it. Modified by VgRt6 at 11:05 PM 4-2-2006
Now: '99.5 Jetta GLS VR6 (282,000 miles and counting! Then: '90 Passat GL 16v -
) - Stupid CEL )
(RIP - i.e., Rest in Pain!!! in a junkyard somewhere you LEMON POS - still loved her though
* The Official VgRt6 MKIV/VR6 DIY Thread Master List * VgRt6 Moderator Introduction & Prepping The Engine So That It Can Be Raised INTRODUCTION 1. The main water pump is located on the passenger's side of the engine, as indicated by the yellow arrow in the picture below. Offline Member Since « » 11:42 AM 12-1 6-2003
3-7-2002 15876 posts Germantown MD 99.5 Jetta GLS VR6
2. The main water pump is driven by the serpentine belt and is located just below and to the rear of the serpentine belt tensioner pulley. The water pump pulley is indicated by the yellow arrow in the picture below. Unfortunately, the pump sits just to the driver's side of the frame support for the passenger's side engine mount (support is indicated by the red arrow in the picture below - Note: the picture below was taken with the engine already raised, so the access to the pump/pulley bolts is even less than shown). While the pump is approximately 4.15" in length, there is only approximately 1.5" of space between the pump pulley and the frame support. Therefore, in order to get the pump out of the block, the engine needs to be raised nearly 2" and pushed towards the driver's side of the engine bay, and the pump pulley needs to be removed. Raising the engine requires that the passenger's side engine mount and the tranny pendulum mount be disconnected and that the driver's side tranny mount be loosened. It also requires that some items attached to the engine and mounts be removed or temporarily moved out of the way. These steps will be covered in detail in the next sections.
PREPPING THE ENGINE SO THAT IT CAN BE RAISED 3. The replacement of the water pump can be done with the car on the ground or up on ramps or jack stands as you don't need much access to the bottom of the car. That being said, I recommend that you raise the front end of the car to do the procedure. This will allow you to check the engine and exhaust (especially oxygen sensors) as they're being raised to make sure that no binding occurs. Raising the car also provides extra clearance below the oilpan and tranny so that a nice big block of wood can be used between these items and a jack when raising up the engine. 4. Remove the long cover piece on the passenger's side of the engine. To do this, remove the two T30 Torx screws (indicated by the yellow arrows in the picture below) and carefully pull upward on the cover piece.
In order to move the CET out of the way enough to gain access to the rear engine mount bolt. Disconnect the CET from the body by removing the two Phillips head screws indicated by the yellow arrows in the picture below. unclip the sensor leads from the CET and coolant hose (white arrows in picture below). you may need to unclip (yellow arrow in picture below) the lower CET hose (red arrow in picture below) and move it out from between the two hoses on either side (green arrows in picture below). First. unclip the coolant hose from the top of the PSR (yellow arrows in picture below) and then unclip the same coolant hose from the upper CET hose (green arrow in picture below). In addition. Finally. 6. The power steering reservoir (PSR . disconnect the harness connector for the coolant level sensor on the CET (red arrow in picture below). 7.white ball with blue cap in picture below) blocks access to the rear engine mount bolt and needs to be moved out of the way. Next. the coolant expansion tank (CET .5.black tank with green cap in picture below) sits directly on top of the passenger's side engine mount and needs to be able to move up freely when the engine is raised. .
Remove the 13mm bolt that connects the PSR support to the body. The pipe is attached to the manifold by two 6mm hex bolts. one of which is indicated by the green arrow in the picture below. The other bolt used to secure this pipe will be removed in step 14.8. as indicated by the yellow arrow in the picture below. This pipe needs to be disconnected or it will hit the low pressure service valve of the A/C system (red arrow in picture below) when the engine is raised. The yellow arrow in the picture below points to a metal coolant pipe (from the secondary radiator) that sits just below and to the front of the upper intake manifold. . Remove the small engine cover piece with the VW logo on it by removing the single T30 Torx screw (red arrow in the picture below) and unclipping the three spark plug wires from their respective channels (yellow arrows in picture below). 10. 9. Remove this bolt.
Disconnect the hood release bowden cable (yellow arrow in the picture below) from the trim piece just to the passenger's side of the one just removed. 13. . Remove the trim piece by removing the two Phillips head screws indicated by the yellow arrows in the picture below and sliding the piece toward the rear of the car and up and out. Remove the trim piece in front of the battery box by removing the two Phillips head screws indicated by the yellow arrows in the picture below and sliding the piece upwards.11. 12.
It's a very tight fit. Move the metal coolant pipe (yellow arrow in picture below) towards the front of the car and down along side the hard. from pushing the coolant pipe against the A/C service valve discussed in step 9.part of the secondary air injection system?). which will raise up with the engine. but it's possible to get a short hex wrench (shown) in between the manifold and front end to remove the bolt. The second 6mm hex bolt that secures the metal coolant pipe to the manifold is just to the driver's side of the first intake runner. 15. This step may require some hand contorting and a bit of time. This will prevent the hose. flexible hose (red arrow in picture below .14. Remove the lower sound absorber panel from underneath the engine/tranny (red arrow in picture below) by removing the four T25 Torx screws that attach it to the car. There are two screws on each side of the panel. The two on the passenger's side of the panel are indicated by the yellow arrows in the picture below. 16. as indicated by the yellow arrow in the picture. .
so I just let the coolant in the block (hard to guess how much. Unfortunately. some coolant will spill out of the block. e. The choice is yours. 20. I promise ). Disconnect the harness connector from the MAF sensor. but I say around 2 quarts or so) spill out onto the ground. the drain sits directly above the driver's side splash guard (the one being moved aside in the picture) and as a result. there is a depression in the cover which allows the connector to be removed without removing the cover. When you finally remove the water pump from the engine (we're getting there. To drain the coolant from the radiator. The coolant will come out of the drain marked by the red arrow. you may need to remove the relay box cover (indicated by the white arrow in the picture below) to be able to do this. turn the knob indicated by the yellow arrow in the picture below (on the lower driver's side of the radiator) approximately 45° and pull out. .) It is not necessary to drain the coolant from the radiator when replacing the water pump. If you want to prevent this. 19. You may want to consider flushing out the heater core if you're replacing your coolant. On early model-year MKIV cars. which is located at the rear driver's side of the engine bay. must be temporarily moved out of the way to gain access to the tranny mount. Unfortunately. The driver's side tranny mount sits directly below the intake air filter box. the upper coolant hose is very difficult to reach. (Note that there will still be coolant present in the heater core. 18. especially if you're switching formulations. G11 to G12. Since my coolant was original (had 145k miles on it). The air filter box. An option is to just let the little bit of coolant spill out of the block when removing the pump and then top off the coolant when the new pump is in. as indicated by the yellow arrow in the picture below. you can remove the upper oil cooler hose to drain the block. I recommend placing a tube on the end of the drain to direct the coolant into a bucket or other large container. On later model-year MKIV cars. the coolant will hit this piece when it comes out and make a mess.17. I decided to drain the existing coolant from the radiator and put all new coolant in when the pump replacement was done.g.
(FYI. revealing the air filter element. 24. only unscrew them until they come out of the lower box (they can slide up 1/4"-1/2" easily when this point is reached).) . The screws are indicated by the yellow arrows in the picture below. 22. Unscrew the two Phillips head screws that hold the cover of the air filter box to the main section of the box.the intake hose is still connected). indicated by the yellow arrows in the picture below. The other side of the air filter box cover is held down by four tabs. the red arrows in the picture below indicate one of the tabs that hold the front of the air box cover in place. you need to lift up on the rear slightly (red arrow in picture below) to release the tabs and then slide the cover towards the rear of the car (green arrow in picture below).21. Disconnect the hard plastic hose for the secondary air injection system by pressing in on the two ribbed tabs (yellow arrows in picture below) and pulling the hose down and off. The picture below shows the air box with the cover removed and held up and to the side (be gentle . You do not need to remove the screws completely. 23. To remove the cover.
slide the air box toward the passenger's side of the car and up and out of the car.25. 26. The air box is secured on the driver's side by the intake snorkel (hole for snorkel can be seen in the picture below) and a rubber rod (yellow arrow in picture below). Lay the air box cover back on top of the air box (do not reconnect the cover) and then remove the rear 10mm bolt that attaches the air box to the car. The rear bolt is indicated by the yellow arrow in the picture below. These make the air box difficult to remove. . The bolt is down between the air box and battery box .you'll need a long extension to get to it. 27. While holding the air box cover up and out of the way (a second pair of hands is helpful). Remove the front 10mm bolt that attaches the air box to the car.
Rest in Pain!!! in a junkyard somewhere you LEMON POS .5 Jetta GLS VR6 (282.5 Jetta GLS VR6 WARNING: THE FOLLOWING STEPS REQUIRE THAT YOU DISCONNECT THE ENGINE/TRANNY MOUNTS FROM THE CAR.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * VgRt6 Moderator Raising The Engine To Access The Water Pump and Replacing The Water Pump RAISING THE ENGINE TO ACCESS THE WATER PUMP « » 11:43 AM 12-1 6-2003 Offline Member Since 3-7-2002 15876 posts Germantown MD 99. so be ready for this when you remove the second bolt.. PLEASE BE VERY CAREFUL WHILE DOING THESE STEPS AND THEREAFTER UNTIL THE ENGINE/TRANNY IS RESECURED.e. The engine may rotate slightly when the bolts are removed. Modified by VgRt6 at 7:53 PM 5-13-2004 Gary Now: '99. With the air box now out. 29.i. now is a good time to replace your air filter element if it's been neglected. you should be able to see the driver's side tranny mount.000 miles and counting! Then: '90 Passat GL 16v - ) . Reach under the car and remove the two 16mm bolts that secure the tranny pendulum mount to the tranny. THERE IS ALWAYS THE POSSIBILITY THAT THE ENGINE/TRANNY MAY MOVE AND FALL WHILE IT IS DISCONNECTED. These bolts are indicated by the yellow arrows in the picture below. 28.Stupid CEL ) (RIP .the shorter bolt is towards the front of the car and the longer bolt is towards the rear. Also remember to keep track of which bolt goes where .Note: With the air box apart. . It is indicated by the red arrow in the picture below.
I REPEAT. PLACE A JACK AND PIECE OF WOOD UNDERNEATH THE OILPAN FIRST!!! . DO NOT REMOVE THE BOLTS THAT CONNECT THE ENGINE MOUNT TO THE ENGINE ITSELF (LOCATED BETWEEN THE ENGINE MOUNT AND THE ENGINE)!!! THESE BOLTS SUPPORT THE WEIGHT OF THE ENGINE. WARNING: MAKE SURE THAT YOU ONLY REMOVE THE BOLTS THAT CONNECT THE ENGINE MOUNT TO THE BODY!!! THESE BOLTS ONLY HOLD THE ENGINE MOUNT IN PLACE AND DO NOT SUPPORT THE WEIGHT OF THE ENGINE. 31. DO NOT. THE ENGINE WILL DROP!!! IF YOU WANT TO REMOVE THESE BOLTS.30. Remove the front 16mm passenger's side engine mount-to-body bolt indicated by the yellow arrow in the picture below. IF YOU REMOVE THEM WITHOUT SUPPORTING THE WEIGHT OF THE ENGINE FROM ABOVE OR BELOW. Remove the rear 16mm passenger's side engine mount-to-body bolt indicated by the yellow arrow in the picture below.
If the engine is jacked up with the wood against this bump. 36.. THEN STOP IMMEDIATELY AND LOWER THE ENGINE BACK DOWN SLIGHTLY. Note that the engine cover (yellow arrow) is roughly even with the front end trim. it will concentrate the load of the engine on this spot and could possibly damage the oilpan. The pictures below show that the top of the engine and the passenger's side engine mount were raised approximately 1 3/4" before binding occurred. If the engine is raised any further.a one foot long 2x6 is a good choice) under the passenger's side of the oilpan. After the suspension is unloaded. I don't recommend jacking the engine up anymore than this or you may possibly damage parts of the engine or exhaust system. Most notable are the oxygen sensors on the catalytic converter. THIS WILL BE PERFORMED AFTER LIFTING THE PASSENGER'S SIDE OF THE ENGINE. NOTE: THE DRIVER'S SIDE TRANNY MOUNT HAS NOT BEEN DISCONNECTED YET. Place a jack and piece of wood (for protection and to spread the load . 34. Slowly jack up the passenger's side of the engine. the sensor leads will smash into the underside of the car and possibly be damaged. Also make sure to avoid placing the piece of wood up against the bump in the oilpan where the drain plug screws into (green arrow in picture below). . BEFORE JACKING UP THE ENGINE AGAIN. IT'S FINALLY TIME TO JACK UP THE ENGINE!!! The picture below shows the height of the engine before lifting.32. If the car is on stands. The engine can be jacked up approximately 1 3/4" before binding will occur. WARNING: IF THE ENGINE OR EXHAUST BINDS BEFORE REACHING 1 3/4" OR SO (I. If the car is on the ground or on ramps (suspension is still loaded). The additional clearance gained by raising the engine 1 3/4 " is just enough to get the water pump out . then both the car and engine will lift up initially as the engine is raised since the suspension is being unloaded.the engine will begin to rise immediately. DETERMINE WHAT IS PREVENTING THE ENGINE FROM BEING RAISED AND CORRECT THE PROBLEM. the engine will rise by itself and the car body will remain at the same height. 35. THE CAR STARTS LIFTING AGAIN AS THE ENGINE IS JACKED UP). then the above will not occur .you shouldn't need to raise it any further. Make sure the wood is against the flat part of the oil pan (yellow arrows in picture below) and not against the sloped part (red arrow in picture below).E. 33.
If necessary. When you do this. 38.37. This is a good thing as it gives more clearance for getting the water pump out. 39. THE TRANNY WILL DROP AND COULD POSSIBLY CAUSE THE ENGINE TO FALL. You do not need to remove them completely. Make sure that tranny does not hang by the loosened bolts. Loosen the two 18mm tranny mount-to-tranny bolts (indicated by the red arrows in the picture below) approximately 1". the engine may shift slightly towards the driver's side of the car since the tranny mount-to-tranny bolts actually sit in slots in the tranny mount. Even with the engine now jacked up. Place a second jack and piece of wood underneath the tranny. it is still necessary to slide the entire engine and tranny over towards the driver's side of the engine to get the water pump out of the block. adjust the height of the jack under the tranny so that the weight of the tranny is supported by the jack. Try to find a nice flat area where the block of wood can apply force the the tranny evenly. WARNING: DO NOT PERFORM THE NEXT STEP WITHOUT MAKING SURE THAT THE JACK/WOOD IS IN PLACE UNDERNEATH THE TRANNY. Jack up on the tranny very slightly. not enough to actually jack up the tranny. . IF THE JACK/WOOD IS NOT IN PLACE. just enough to support the weight once the tranny mount bolts are loosened. THE NEXT STEP INVOLVES LOOSENING THE BOLTS THAT SECURE THE TRANNY MOUNT TO THE TRANNY. Such an area is indicated by the yellow arrows in the picture below.
it should now be possible to remove the water pump from the block and install a new one. but the socket seems to work better. REPLACING THE WATER PUMP 41. (Note: If belt tension is not sufficient to keep the pulley from spinning while removing the pulley bolts. such as a small hex wrench.) NOTE: PLEASE READ STEPS 42 THROUGH 44 BEFORE ATTEMPTING TO REMOVE THE PULLEY BOLTS. Therefore. 43. you can remove both together since the motor mount support is not in the way. Be warned that the heads on the pulley bolts are extremely shallow and can strip easily. The picture below shows a socket wrench and 6mm hex socket being used to remove the pump pulley bolts (yellow arrows). follow steps 3 and 4 in the following DIY .) The second is to loosen the belt on the pulley (refer to steps 3 and 4 in the serpentine belt DIY) and insert something into one of the pump bolt access holes (indicated by the yellow arrow in the picture below). While each pulley bolt is being removed. The first is to use the force applied by the tightened serpentine belt to hold the pulley in place while the bolts are loosened. you will need to rotate the pulley until the bolt being removed clears the motor mount frame support. Make sure that you insert the hex socket/wrench into the bolt head completely and apply side pressure to help prevent stripping from occurring. There are two easy ways to accomplish this. there may be enough clearance between the pump and motor mount frame support to remove the bolts without having to rotate the pulley. While it is possible to unbolt the pump from the block without first removing the belt pulley (there are holes in the pulley which provide access to the pump bolts behind it). you must first remove the pulley and then remove the pump. Push the engine/tranny over towards the driver's side as far as it will go. If you are using a socket wrench with a hex socket to remove the pump bolts. The other two bolts will be blocked by the frame support and the pulley will need to be rotated again (and again) to get the other bolts out. . as show in the picture above. To rotate the pulley. It may be helpful to have someone lift and pull the tranny over from the driver's side of the car while someone else pushes the engine over from the passenger's side.40. 44. 42. If you are using a regular hex wrench to remove the pulley bolts. but on MKIV the pulley and pump must be removed separately. there is still not enough clearance to remove the pump and pulley together. To do this. the pulley must be held in place and kept from spinning. It is also a good idea to spray the bolts with a penetrating lubricant prior to removal. Either works well. to pin the pulley against the block and keep it from spinning. With the engine raised and pushed over towards the driver's side. You can also use a regular hex wrench. the tension on the serpentine belt needs to be removed temporarily.SERPENTINE BELT DIY. use the next method. (On a MKIII.
use a large screwdriver or other similar object to carefully pry the pump from the block. If not. remove the serpentine belt tensioner in order to provide more clearance for removing the pump from the block.45. 48. If you did not drain the coolant from the block. that means they have traveled into the cooling system and are stuck somewhere. it should slide out easily. the pump will not come out of the block easily once the bolts are removed. Remove the three 6 mm hex bolts that attach the water pump to the block. We put some anti-seize on the bolt threads to make sure they'd come out easy next time (although hopefully there won't be a next time). you may need to twist it slightly to clear the motor mount frame support or you may need to push the engine over towards the driver's side some more. Again. If it doesn't. These bolts are indicated by the yellow arrows in the picture below. be careful not to strip the bolts while removing them. When I removed my pump. you should see a big hole in the block. I discovered that one of the impeller fins had broken off. coolant will spill out as the pump is removed. insert the bolts and tighten to 11 ft-lbs. Check to make sure that all of the fins on the existing pump impeller are still intact. insert the bolts and tighten to 18 ft-lbs. Once dislodged. Install the belt pulley on the new pump. To do this. follow steps 3 through 5 in the serpentine belt DIY. We put some Loctite on the pulley bolts to help ensure that the pulley didn't come flying off the pump while spinning at thousands of RPMs. Lubricate the new o-ring for the new pump with some coolant and install it in the groove on the pump. as indicated by the yellow arrow in the picture below. 49. Next. 47. install the new pump into the block. There is no easy way to retrieve the pieces except to disassemble and inspect parts of the cooling system. Once the pump is out. 51. 52. 53. Prior to installing the new water pump. such as the thermostat and radiator. . If some have broken off. clean the pump mating surface around the hole in the block with a rag or paper towel to remove any junk. line up the bolt holes (they only line up one way). 46. I'm not going to worry about it unless I have cooling system problems. 50. If the pump will not slide out completely. More than likely. I didn't feel like spending the time and effort to find it so I just left it in the system. Reinstall the serpentine belt tensioner. Once the pulley has been removed from the pump. make sure the belt is on all of the pulleys correctly and reapply tension to the belt. check inside the pump hole to see if they are in there.
oh well. remove return line.54. but the sheer volume of *stuff* that needs to be removed just to gain access to the water pump bolts is astounding.. Modified by VgRt6 at 2:11 PM 12-16-2003 I'm jealous.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * DrTacoElf Member Offline Member Since 7-1 4-2003 1125 posts Beverly Hills CA holy cow thats a lot of info « » 1:22 PM 12-1 6-2003 Daemon42 Member Re: (DrTacoElf) Very nice writeup. Someone needs to add a link to this to the 12v VR6 FAQ and you might consider submitting it the maintainer of the gti-vr6 library to compliment the existing Mk3 instructions.30 ft-lbs + 90° (stretch bolt) .. The only real modification I make for the water pump. TT Borla Exhaust « » 2:10 PM 12-1 6-2003 Re: (Daemon42) Thanks Ian. I needed only to disconnect blower pipes.30 ft-lbs + 90° (stretch bolt) . By comparison I replaced the alternator yesterday on my Mk3 and to get to it. « » 2:00 PM 12-1 6-2003 Offline Member Since 2-9-2001 17997 posts Lakewood CO 2004 R32 Blue But holy smokes. but not this. but still goes pretty quick. but accessing the MKIV motor mount bolts is a lot easier on the MKIV no need for hand contortions or special tools. . You should now have a new.Gone & Forgotten POS RIP VgRt6 Moderator : 1988 VW Jetta GL 2. but the sheer volume of *stuff* that needs to be removed just to gain access to the water pump bolts is astounding. unbolt supercharger. 55.. you MkIV guys have a lot of clutter in the engine bay.pendulum mount-to-tranny bolt. K&N Intake. I knew there was more crap on the passenger side.000 miles and counting! Then: '90 Passat GL 16v - ) . nothing else moved. You're write-up in the gti-vr6 library was my starting point when doing this job. nothing else moved. It's really only a couple of bolts and unclipping a few hoses. Now lower the engine. unbolt supercharger. ian No Doubt. I needed only to disconnect blower pipes. lift out of the way.5 Jetta GLS VR6 (282. or removed). you MkIV guys have a lot of clutter in the engine bay.i.Stupid CEL ) (RIP . « » 2:10 PM 12-1 6-2003 Offline Member Since 7-1 1-2002 1553 posts Mechanicsburg PA 2001 Jetta Turbo GLS But holy smokes. No wonder it needed a whole new set of instructions. fully-functional water pump. lift out of the way. excellent job 2001 Jetta Turbo GLS 1988 VW Jetta GL 1. front .44 ft-lbs + 90° (stretch bolt) 56.30 ft-lbs . remove return line. Rest in Pain!!! in a junkyard somewhere you LEMON POS . rear . Enjoy the new R32 when it arrives. The torque specs for the engine and tranny mount bolts are as follows: .8L 8v . Enjoy the fact that you just saved a ton of money by doing this yourself! Modified by VgRt6 at 9:12 AM 3-6-2007 Gary Now: '99. By comparison I replaced the alternator yesterday on my Mk3 and to get to it.. Looking forward to my R32..driver's side mount-to-tranny bolts . Looking forward to my R32. The only real modification I make for the water pump. is to loosen the two rear motor mounts so the engine can be raised further without binding. That's it.passenger's side engine mount-to-body bolts .5 Jetta GLS VR6 It may seem like a lot. There may be less stuff to move out of the way on the MKIII. Someone needs to add a link to this to the 12v VR6 FAQ and you might consider submitting it the maintainer of the gti-vr6 library to compliment the existing Mk3 instructions. remove front motor mount bolt. raise engine (that's right. or removed). Removing the air box on the driver's side is a little more work. but it's really not that bad. If you know what to remove. you can get it all out of the way in 15 mins or so.8L VR6..e. but not this. oh well. I knew there was more crap on the passenger side. reattach the tranny and engine mounts and reinstall all of the parts that were moved or removed by following steps 3 through 40 in reverse..pendulum mount-to-tranny bolt. No wonder it needed a whole new set of instructions. remove front motor mount bolt. ian PwrVdubGuy Member Re: (Daemon42) Quote. Offline Member Since 3-7-2002 15876 posts Germantown MD 99. originally posted by Daemon42 » Very nice writeup. is to loosen the two rear motor mounts so the engine can be raised further without binding. raise engine (that's right.
e.i. Now I have to start over! Germantown MD 99.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * sicrado Member « » 4:12 PM 12-1 6-2003 Offline Member Since 4-3 0-2002 2879 posts sic jersey shore 91 GTI.01 Eurovan GLS. Daemon42 Member Re: (BCDS2003T) « » 9:25 PM 12-1 6-2003 .e.Replacing the main water pump on a MKIV 12v VR6 (VgRt6) « » 3:20 PM 12-1 6-2003 once again an excellent write up VgRt6 Moderator Re: (James 93SLC) Quote. TT Exhaust.Stupid CEL ) (RIP .Gary Now: '99..i. It's at the end of paragraph 4 at the top and not an actual "step". 93 Corrado props -Sean- BCDS2003T Member Offline Member Since 9-1 7-2001 342 posts Baltimore MD 2000 Jetta 1. Edit: I forgot that I actually did mention lunch and beer in the DIY.04 COBRA.000 miles and counting! Then: '90 Passat GL 16v - ) .Stupid CEL ) (RIP . originally posted by James 93SLC » I think you missed a step Gary « » 3:29 PM 12-1 6-2003 Offline Member Since 3-7-2002 15876 posts Where is the lunch break run to Quiznos? And don't forget the Crap.5 Jetta GLS VR6 (282. Modified by VgRt6 at 4:20 PM 12-16-2003 Gary Now: '99.8T.92 F-150 300 inliner Re: DIY . I'm saving that step for the 432 page timing chain and tensioner DIY.. 1988 Jetta 16V Re: (VgRt6) « » 9:18 PM 12-1 6-2003 Yeah Gary-You should also mention that it goes much quicker when the peanut gallery actually helps instead of whining about how cold it is..000 miles and counting! Then: '90 Passat GL 16v - ) .00 GTi VR6.5 Jetta GLS VR6 Just kidding. Rest in Pain!!! in a junkyard somewhere you LEMON POS . Koni..Turn2. TT Chip The 12V VR6 headgasket/timing chain/cooling system parts list Replacing the Corrado hood release + part numbers Where is the lunch break run to Quiznos? And don't forget the corpsedub Member Offline Member Since 8-3-2001 5029 posts san francisco 06 330i. Rest in Pain!!! in a junkyard somewhere you LEMON POS .5 Jetta GLS VR6 (282.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * James 93SLC Member Re: (VgRt6) « » 2:42 PM 12-1 6-2003 I think you missed a step Gary Offline Member Since 9-2 7-2000 2736 posts Northeast OH 93 Corrado SLC & 02 Passat Variant V6 4Motion James 93 SLC .
801 60ft.5 Jetta GLS VR6 Gary Now: '99. although handling some of the metal blower parts was less than fun. but luckily we were in a garage with the doors closed. originally posted by C2Motorsports » Nice write-up.000 miles and counting! Then: '90 Passat GL 16v - ) .Replacing the main water pump on a MKIV 12v VR6 (T99inFL) « » 4:18 PM 12-2 1-2003 very nice. As I said above.e. Rest in Pain!!! in a junkyard somewhere you LEMON POS .. It was relatively balmy in there .Replacing the main water pump on a MKIV 12v VR6 (dancdas) « » 7:06 PM 12-2 1-2003 .Stupid CEL ) (RIP .5 Jetta GLS VR6 (282.706 @98. I'll be doing my timing chains in the next month or two and promised James and the peanut gallery that I'd get a space heater so I didn't have to listen to them whine.. 2G DSM 6 Bolt Turbo AWD.. and somewhat colder than that. Gary Now: '99. A couple 500 watt halogen work lamps make pretty decent space heaters. When I finished. Offline Member Since 3-7-2002 15876 posts Germantown MD 99.8T 1999. 502. I've only got about 4 or 5 gashes in the back of my hands. YOUR Jetta GLX did not come with 300hp from the factory VgRt6 Moderator C2Motorsports Inc. but next time would you mind going into a little more depth and detail Offline Member Since 1 1-2 5-2003 3801 posts Louisville KY You mean.Replacing the main water pump on a MKIV 12v VR6 (VgRt6) « » 3:53 AM 12-2 0-2003 VgRT6: Very nice write up.i.5 Jetta GLS VR6 I'll keep that in mind for next time. I did my alternator last night.5 Silver Jetta VR6.rot in hell you money pit! " 0-60 in 30 seconds can still earn a speeding ticket. 1.3660 | Engineering | Fabrication | Manufacturing High Performance Automotive Hardware and Software Southern Worthersee | DurtyFest | DubWars | Waterfest | DATR | H2O | We might show up in your town too Re: (C2Motorsports) Quote.9mph.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * T99inFL Member Offline Member Since 8-4-1999 455 posts Sunrise Florida T99inFL-> 2003 Gray Jetta 1. ian VgRt6 Moderator Re: (Daemon42) « » 9:41 PM 12-1 6-2003 Haha." Re: DIY . I'm Norwegian so the cold doesn't bother me a bit..e.000 miles and counting! Then: '90 Passat GL 16v - ) .still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * C2Motorsports Advertiser Re: (VgRt6) « » 7:58 AM 12-1 7-2003 Nice write-up.Stupid CEL ) (RIP .Offline Member Since 2-9-2001 17997 posts Lakewood CO 2004 R32 Blue Tell ya what.. tdigti Member Offline Re: DIY .5 Jetta GLS VR6 (282. 13... probably upper 30's. Rest in Pain!!! in a junkyard somewhere you LEMON POS . The light kept me reasonably warm. When I started it was 32 degrees and windy. dude! dancdas Member Offline Member Since 5-2 7-2003 1480 posts DSM Re: DIY . i'm planning to do mine within the next couple months and it doesnt look like you need to disconnect so many things to lift the motor.895. it was dark. It was 28-30 degrees when we did the water pump. wow that looks like a lot harder then the mkIII vr's.i.. but next time would you mind going into a little more depth and detail « » 8:55 AM 12-1 7-2003 Offline Member Since 3-7-2002 15876 posts Germantown MD 99.
Somebody buy this dude a beer when he's in your town.34870 BILLET VR6 Keychains http://www. this time for good. I NEED the DIY you posted on the Timing Chain.e. VgRt6 Moderator Re: (DrivenDriversEdition) » The link to the timing chain DIY is in the link in my signature. Paul 92 SLC . very informative write-up.just support engine.http://www.vwfixx.. Offline Member Since 3-7-2002 15876 posts Germantown MD 99..vwfixx. and remove/replace pump. originally posted by tdigti » « » 7:38 PM 12-2 1-2003 it's stuff like this that make me think I should have bought a 1.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * VgRt6 Moderator Re: DIY . long live the memory of Pope John Paul II VgRt6 Moderator Re: DIY .. it looks like the job on the corrado vr6 is much easier .5 Jetta GLS VR6 Gary Thanks. Dino oil rules.vwfixx. raise engine. .still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * DrivenDriversEdition Member » « » 11:54 AM 5-1 4-2004 Offline Member Since 1 1-2 4-2003 115 posts Ellicott City MD 89 BBM I don't need the Water pump DIY.TRACK TESTED !!! http://www. Good job dude.8T..i. Puralator filters rock.5 Jetta GLS VR6 Gary Now: '99. Shipped -.replaced water pump pi2060@yahoo. Gary Offline Member Since 3-7-2002 15876 posts Germantown MD 99...8T.5 Jetta GLS VR6 (282.com/forums/i. Gary « » 12:14 PM 5-1 4-2004 Offline Member Since 3-7-2002 15876 posts Germantown MD 99.Replacing the main water pump on a MKIV 12v VR6 (tdigti) Quote. Good job dude. This is what keeps people coming to the Tex.Stupid CEL ) (RIP .000 miles and counting! Then: '90 Passat GL 16v - ) .Stupid CEL ) (RIP . You do realize that the DIY is for a VR6 though.5 Jetta GLS VR6 (282.com $95 Metal VR6 Crack Pipes. Rest in Pain!!! in a junkyard somewhere you LEMON POS .Member Since 6-2 0-2002 723 posts Roanoke.i.. This is what keeps people coming to the Tex. very informative write-up.97415 Custom Made VR6 Intake Mani Shift Rod Bushings .000 miles and counting! Then: '90 Passat GL 16v - ) .e.Replacing the main water pump on a MKIV 12v VR6 (VgRt6) » « » 8:07 PM 5-1 3-2004 Pics are back online .000 miles and counting! Then: '90 Passat GL 16v - ) . And for once. Virginia 2007 BMW 1200rt (sex machine) it's stuff like this that make me think I should have bought a 1..34080 .i.5 Jetta GLS VR6 Gary Now: '99.Stupid CEL ) (RIP .5 Jetta GLS VR6 (282. Rest in Pain!!! in a junkyard somewhere you LEMON POS .still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * A2T Member Offline Member Since 1 1-9-2000 2046 posts Atlanta.com/forums/i. don't you? Now: '99.e.. GA 92 SLC Re: (VgRt6) » « » 3:57 PM 5-1 4-2004 Excellent. Rest in Pain!!! in a junkyard somewhere you LEMON POS .com/forums/i.. undo mounts..
8/1/02 mk3gti much easier.8TQMS 75k 06 Chevy Colorado 5spd 59k f0xf0702k1 Member Offline Member Since 3-2 9-2002 4232 posts West Chester PA 1991 GLI. I refilled my coolant through the reservoir as much as I could and then I turned on the engine and topped it off as the coolant was sucked into the system. I replaced my belt and re-greased the bearing in my pulley tensioner (you can pop out the rubber seals and fill the bearing with wheel bearing grease). good writeup Re: DIY . A couple of comments: I was able to do this with only one floor jack and 2 jack stands to raise the front end of the car and provide more clearance. my 99. Re: (A2T) » « » 11:20 AM 12-2 0-2004 Offline Member Since 7-2 7-1999 7839 posts NJ MKIV GTI GLX Just did this yesterday." JamesGti1. You have to be careful not to damage the sealing surface on the engine block. hello mk4 VR6 « » 9:26 PM 8-3 0-2005 Re: DIY . good writeup i just did mine today. Luckily that was a 10 minute swap. This operation requires some time and care.5 GTI GLX had a mk3 Bosch auxiliary pump (i replaced that one too. winter build up http://www. I drained everything except the heater circuit and I had to add almost exactly 1 gallon of coolant and 1 gallon of distilled water.Eric 1991 Jetta GLI VR6 supercharged.Replacing the main water pump on a MKIV 12v VR6 (VgRt6) » . My Gallery olaf Member Offline Member Since 6-8-1999 768 posts Harvard MA Re: DIY .Replacing the main water pump on a MKIV 12v VR6 (VgRt6) » « » 2:11 PM 7-2-2005 This was an excellent write-up.8T Member Offline Member Since 2-3-2004 1282 posts thanks gary. your diy are always great Laurel md vr6t Goodbye mk4 1.Replacing the main water pump on a MKIV 12v VR6 (olaf) » « » 6:47 PM 7-2-2005 fourthchirpin Member Re: DIY . I could raise my engine almost 3 inches with no clearance problems.8T. While I was at it. It was stuck on there pretty good. After a test drive and cool-down period I re-checked the coolant level and topped it off. the motor was burnt out. Modified by olaf at 6:24 PM 7-2-2005 -olaf 01 GTI 1. I had to carefully use a flat head screwdriver and hammer to free the pump from the block. with a power steering whine . and yes. It takes a genius to make the most complex things simple. Similarly. It saved me a lot of time and money.net > your shop all i can say is im glad i have a mk3 much easier. Thanks again Gary. Perhaps the GTI's are slightly different? My main water pump had a metal impeller. originally posted by f0xf0702k1 » all i can say is im glad i have a mk3 « » 4:58 PM 8-3 0-2005 Online Member Since 1 1-1 9-2004 7873 posts EST.race-shop. Thanks. but you will succeed if you are a decent back-yard mechanic and you have the right tools. But the DIY post was an incredible time saver and help. Obviously there was still some old coolant in the system. thanks "RACING IMPROVES THE BREED" West Indian Crew "a Fool can make the most simple things complex. Well done.EPilot Member. What a crazy job.Replacing the main water pump on a MKIV 12v VR6 (f0xf0702k1) » Quote. however it began to leak sometime last year and began progressively squeaking more and more.8T 141k 05 A4 Avant 1.
...?When i turn my AC on it either seems to get louder or a whole new chirp starts thats louder than the other.jack up car lower engine.a friend who is very mechanically inclined. Gary Offline Member Since 3-7-2002 15876 posts Germantown MD 99..LABOR ALONE IS $550!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! now thats insane Re: DIY ...8l 12v VR6 Engine Forum 2....5 Jetta GLS VR6 Gary Now: '99....i. ANY suggestions on what is wrong VgRt6 Moderator Re: DIY .Replacing the main water pump on a MKIV 12v VR6 (VgRt6) » « » 8:34 PM 9-1 9-2005 ogvr6 Member Offline Member Since 1 1-3-2004 183 posts north fl mk4 VR6 Re: DIY ....5 hrs.... not common....thank you very much again.They said for the part alone (no new pulley) is $180.when mine went...but he couldn't have done it without the great info that I got from the vr6 forum.Replacing the main water pump on a MKIV 12v VR6 (smoothbomber23) » « » 9:40 PM 9-1 9-2005 many thanks for all the info and dIy's on the vortex.Replacing the main water pump on a MKIV 12v VR6 (VgRt6) » « » 5:23 PM 9-1 8-2005 How do i know if it is my water pump that is making that noise? Its like a chirping when the car is running.. I called my local v dub dealer and asked them what they charged for replacing a broken water pump. Why is common sense........ If that doesn't help...after sharing this info....8l 1 2v VR6 Engine Forum 6 Quick Reply .smoothbomber23 Member Offline Member Since 9-1 8-2005 5 posts Stafford VA 2000 GTI VR6 Re: DIY ... then I would use a mechanic's stethoscope to try and pinpoint the source of the noise. you're an absolute star! I'm having to do a water pump replacement on my Mk3 VR6 soon and your guide will come in very handy!!! Offline Member Since 8-3 1-2004 50 posts High Wycombe England 1994 Golf VR6 Cabrio now supercharged! Regards..e.. First 1 2 3 4 > Last » Return to 2. v-dub6 Member » « » 7:00 PM 9-2 8-2005 Offline Member Since 4-2 0-2004 35 posts Sarasota Fl 99 vw jetta I recently bought the Graf water pump from Impex. Why is abbreviate such a long word... Ill give that a try and see what happens.Replacing the main water pump on a MKIV 12v VR6 (smoothbomber23) » « » 7:53 PM 9-1 8-2005 It most likely the serpentine belt tensioner pulley.... It also has a metal impeller same part number (vw # 021-121-004-A)..... antera-309 Member Re: (v-dub6) » « » 8:40 PM 9-2 9-2005 VgRt6.went thru passenger wheel well.start to finished about 1.000 miles and counting! Then: '90 Passat GL 16v - ) ...Stupid CEL ) (RIP . See the DIY for fixing that in the link in my signature (it's common for it to dry out and need a re-lubing)....... By the way. Nick.still loved her though * The Official VgRt6 MKIV/VR6 DIY Thread Master List * smoothbomber23 Member Offline Member Since 9-1 8-2005 5 posts Stafford VA 2000 GTI VR6 Alright cool.5 Jetta GLS VR6 (282. Rest in Pain!!! in a junkyard somewhere you LEMON POS .
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