JohnR Posted January 27, 2007 Report Posted January 27, 2007 I have been trying to get my booster heater working properly....it keeps shutting down a minute or so after firing up. The message given was "sensor - temperature too high" so I assumed a problem with a sensor. Gazza reckoned run-on pump which circulates the water. After having a look I think I agree. The mileage checks out (brushes reckoned to fail after 90K - mines done 97K), also, I don't hear this pump running at any time. Measuring blocks in Vag-com, the booster heater sensors all seem to report sensible numbers. When the unit fires up, one of them rises very rapidly until it shuts down (as you'dexpect it if poor water circulation). The pump is fairly well buried above the back of the engine. How do you get it out, and where is it in the TIS? (just spent 20 minute browsing and could not find it.... Is it called something else)? Thanks, John Quote
JohnR Posted January 27, 2007 Author Report Posted January 27, 2007 Forget it....it was easy enough. For anyone else doing it, you just remove the 3 screws and pull off the long cover under the wipers then the pump is just mounted in a couple of rubber rings. once you disconnect the plug you can slide it out. The hardest bit is disconnecting the stupid hose connectors. I binned them and put sume jubilees on that you can get a socket onto. At the mo the pump is bypassed with a piece of 22mm copper. Gazza was quite right....the pump motor only runs if you remove the impeller and flick it to start it. I took the end off the motor and can confirm that the mode of failure is wear of the brushes down to the point where the copper braid snags on the plastic, preventing contact with the commutator. Now if you could find suitable brushes, it would be easy enough to solder some new ones in and put it back together! Failing that, I'll have to look around for a replacement. John Quote
RADIOTWO Posted January 27, 2007 Report Posted January 27, 2007 Hi John, If it is just the carbon brushes, get some that are a bit bigger, and rub them down on a bit of "emery" till they fit ! Radiotwo Quote
JohnR Posted January 29, 2007 Author Report Posted January 29, 2007 (edited) OK. Job sorted. I went to GMF and they quoted Edited January 29, 2007 by JohnR Quote
Bigjeeze Posted January 29, 2007 Report Posted January 29, 2007 Hi John That exactly what I did with mine. I used some old dynamo brushes (well brand new actually in their old box) and cut & filed them to shape- then I struggled to get the lid back on until I drilled the holoes and used two bits of tubular plastic I had. I have bought a second hand pump which needs the job doing so I might well do that one and post the pics. Well done! Quote
NikpV Posted January 29, 2007 Report Posted January 29, 2007 Added to faq - thanks John BJ if you take some pictures can you upload them here - cheers Quote
Guest MATT jr Posted January 29, 2007 Report Posted January 29, 2007 thats good johnR, yet another edition on how to save money! seems daft to replace the whole unit when only a small part of it needs replacing. MJR Quote
JohnR Posted January 30, 2007 Author Report Posted January 30, 2007 Ah....toasted tootsies! Was cold enough for the booster this morning. Was up to temp (90 degrees) in about 3 minutes flat! Just checked with Vag-com and no fault codes so jobs a good-un. Only got the air-con pump to do now. Need a bit more stomach to tackle a rebuild on that but I'm working up to it before the summer! John Quote
Guest MATT jr Posted January 30, 2007 Report Posted January 30, 2007 i will be following your aircon compressor thread - as ours is making a worrying noise! MJR Quote
gazza007 Posted January 30, 2007 Report Posted January 30, 2007 Glad you got it sorted & a DIY job too..Gaz Quote
lazyb5 Posted January 31, 2007 Report Posted January 31, 2007 thanks john guess what i`m doing this weekend i`ve got some spare brushes off an angle grinder which i will size up it could be that these are about right and readily available from hardware shop for those that need themwhat antifreeze did u top up with and how much fluid did u lose doing the job Quote
JohnR Posted January 31, 2007 Author Report Posted January 31, 2007 Because the pump is so high up, you lose next to nothing. I just vented the system (loosen the expansion bottle cap till you hear it vent) to release the pressure, then screwed it on again. I probably lost about a cup full. Before putting the lower pipe back on, I managed to pour about a 1/2 cup of water into the pump and top pipe to get rid of some of the air and prime it. I would have used coolant 12 if I had any. Quote
davgree Posted December 21, 2007 Report Posted December 21, 2007 (edited) Thanks JohnR for your step by step :o Have just replaced brushes this afternoon (brushes c/o secondhand Edited December 21, 2007 by davgree Quote
naim32 Posted January 29, 2008 Report Posted January 29, 2008 Has anyone got any pictures yet? I would like to see a photo of the bushes alongside a ruler to get the correct dimensions. My motor is starting to packup. Also, what's the typical cost from a breakers yard for a spare? Quote
lazyb5 Posted February 4, 2008 Report Posted February 4, 2008 Well despite me saying i was going to do this job a year ago i now need to do it this weekend :lol: The current cost of a new pump from Frauds is Quote
widget Posted April 8, 2008 Report Posted April 8, 2008 Hi, anyone got the fault code for this? Cheers Graham Quote
JohnR Posted April 8, 2008 Author Report Posted April 8, 2008 Its justa a dumb 12v DC pump with no sensors so you won't find a direct code. It shows as an aux heater over temp fault. The After-run pump motor is magnetically coupled to the pump, and before stopping completely, they can exhibit an intermittent over-temp fault. You can hear it when you stop the engine and open the bonnet. Its obvious if its working, a sort of whirring noise from the back. Quote
CORNELL Posted January 31, 2009 Report Posted January 31, 2009 Hi John, Long after your original post, I have changed my brushes today and have a working pump; thanks very much for your assistance in simplifying the task. After some surfing, I discovered some remote control car replacement brushes which were the right size. (5mmx5mmx10mm) decribed as "Trinity P94 Modified motor brushes" (Ebay Item No 170293077631) only Quote
gregers Posted March 13, 2010 Report Posted March 13, 2010 just had to replace the brushes in mine again today,i know last time i done this the replacement brushes i used ended up being rubbed down just a tad too much,but the amount of crud that came out of the unit once i reopened it was surprising.mined you i did borrow them from a very cheap multi tool i had laying around.this time i got hold of some decent ones and took my time doing the reapir,so once again many thanx to john for the detailed instructions :ph34r: still managed to loose my skin,so bloody tight to get the pipes off.still all repaired now. Quote
robpol Posted April 11, 2010 Report Posted April 11, 2010 just had to replace the brushes in mine again today,i know last time i done this the replacement brushes i used ended up being rubbed down just a tad too much,but the amount of crud that came out of the unit once i reopened it was surprising.mined you i did borrow them from a very cheap multi tool i had laying around.this time i got hold of some decent ones and took my time doing the reapir,so once again many thanx to john for the detailed instructions :) still managed to loose my skin,so bloody tight to get the pipes off.still all repaired now. Just lost loads of skin myself trying to get the clips off, only had a rubbish pair of pliers to do it with, so didn't manage too do it which really pee'd me off, so i'll guess i'll try again tomorrow when and if i can get the right tool to do the job...... Quote
Mirez Posted April 11, 2010 Report Posted April 11, 2010 just had to replace the brushes in mine again today,i know last time i done this the replacement brushes i used ended up being rubbed down just a tad too much,but the amount of crud that came out of the unit once i reopened it was surprising.mined you i did borrow them from a very cheap multi tool i had laying around.this time i got hold of some decent ones and took my time doing the reapir,so once again many thanx to john for the detailed instructions :) still managed to loose my skin,so bloody tight to get the pipes off.still all repaired now. Just lost loads of skin myself trying to get the clips off, only had a rubbish pair of pliers to do it with, so didn't manage too do it which really pee'd me off, so i'll guess i'll try again tomorrow when and if i can get the right tool to do the job...... I hate those clips, I have a massive selection of jubilee clips that I replace them with every time I do a job that involves them! Did the run on pump last weekend and just changed the fuel filter ones today ;) Quote
gregers Posted April 11, 2010 Report Posted April 11, 2010 i too changed for jubilee clips,learnt the 1st time :) Quote
robpol Posted April 11, 2010 Report Posted April 11, 2010 So annoyed, was all set to do the pump today...One of the clip has been put on in such awkward position too....couldn't have made it any harder to get off if they tried... Quote
robpol Posted April 11, 2010 Report Posted April 11, 2010 Whats the best tool to get to get the things off? Quote
gregers Posted April 11, 2010 Report Posted April 11, 2010 So annoyed, was all set to do the pump today...One of the clip has been put on in such awkward position too....couldn't have made it any harder to get off if they tried... why do you think there placed where they are,its to stop poor peeps like you and me from attempting the fix in the 1st place, ;) i just used some adjustable pliars to muller them,MAKE SURE you have the correct size jubilee clips before you start the job or your be fubared :) Quote
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