Hi All,
the legend of cooling system issues with my series 2 505 GTi over the last few years has reached the proportions of one of the Norse Sagas. Won't go into the whole tale now but the initiation was fitting a new waterpump (the old one was squealing intermittently). When it was all put back together a squealing noise was still there - worse at idle either disappeared or drowned out at higher revs. Worse than that an occasional bout of overheating still happened. Eventually after eliminating other things the viscous coupling to the fan was the last suspect standing & a replacement (pre-loved) one cured the overheating - but the squeal was still there. Discovered that if I sprayed an absolute shit-ton of belt-dressing the squeal died down, but would always reappear. Getting the car ready for its Rego yesterday I discovered the waterpump pulley was 'wobbling' as it turned - must have been doing this from the beginning but muggins was the second of the not-so-wise monkeys it seems. Couldn't see the same eccentricity happening with the fan - that seemed to be turning smoothly. Reasoning that there must be a locating pin or dog that I hadn't properly engaged when changing the fan over I set about undoing same - first bolt sheared off instantly, as did its opposing neighbour a minute later. At this point decided fronting up for the Rego check was more important than belt squeals so left it & drove gingerly to & from mechanics keeping revs down.
Today I tackled removing the fan & pulley - predictably the other two bolts sheared as well, then there was a horror story when it all came off. The pulley holes have enlarged themselves from round to oval (photo). Also noticed the pulley central hole is a loose fit on the boss of the waterpump - unlike the central hole of the fan coupling which is very tight. I'm guessing a new pulley will be a minimum requirement - not sure any "repair's" going to be successful here. Any tips as to how I can stop this happening again?
Thanks, Rob
the legend of cooling system issues with my series 2 505 GTi over the last few years has reached the proportions of one of the Norse Sagas. Won't go into the whole tale now but the initiation was fitting a new waterpump (the old one was squealing intermittently). When it was all put back together a squealing noise was still there - worse at idle either disappeared or drowned out at higher revs. Worse than that an occasional bout of overheating still happened. Eventually after eliminating other things the viscous coupling to the fan was the last suspect standing & a replacement (pre-loved) one cured the overheating - but the squeal was still there. Discovered that if I sprayed an absolute shit-ton of belt-dressing the squeal died down, but would always reappear. Getting the car ready for its Rego yesterday I discovered the waterpump pulley was 'wobbling' as it turned - must have been doing this from the beginning but muggins was the second of the not-so-wise monkeys it seems. Couldn't see the same eccentricity happening with the fan - that seemed to be turning smoothly. Reasoning that there must be a locating pin or dog that I hadn't properly engaged when changing the fan over I set about undoing same - first bolt sheared off instantly, as did its opposing neighbour a minute later. At this point decided fronting up for the Rego check was more important than belt squeals so left it & drove gingerly to & from mechanics keeping revs down.
Today I tackled removing the fan & pulley - predictably the other two bolts sheared as well, then there was a horror story when it all came off. The pulley holes have enlarged themselves from round to oval (photo). Also noticed the pulley central hole is a loose fit on the boss of the waterpump - unlike the central hole of the fan coupling which is very tight. I'm guessing a new pulley will be a minimum requirement - not sure any "repair's" going to be successful here. Any tips as to how I can stop this happening again?
Thanks, Rob