Aux Coolant Pump

[MadBaz]

I have found an alternative to the electric pump which seems to be now failing on many MK2's

 

Bosch brushless pump

 

And it's available here

 

As it's brushless it should outlast the car, and be quieter, it's certainly cheaper than the original about

[Pemo]

I just ordered one. I'll let you know how it turned out.

[MadBaz]

Oh bugger I forgot about this thread.http://www.fordgalaxy.org.uk/ford/public/style_emoticons/default/ph34r.gif

 

The connector isn't the same, but can be 'adapted' using spade connectors, green wire goes to +ve, and mounting requires tie wraps. Other than that it works fine, booster heater works properly now.

 

Any probs give us a shout.

Edited February 7, 2012 by MadBaz

[Bigjeeze]

I have found an alternative to the electric pump which seems to be now failing on many MK2's

 

Bosch brushless pump

 

And it's available here

 

As it's brushless it should outlast the car, and be quieter, it's certainly cheaper than the original about

[MadBaz]

Instructions:

 

Tools required: 10mm socket, small screwdriver, pliers/pipe clip removal tool, skotchloks x 2/block connector 5amp, x2 spade connectors, stanley knife, needle nose pliers, about 6" of 5 amp cable x2, tie wraps.

 

1, Remove the scuttle tray, x3 10mm bolts.

2, Remove engine cover.

3, I found it easier to disconnect the turbo intake pipe and gently fold out of the way.

4, Lift fuel filter out of bracket, and allow to drop about an inch GENTLY, gives much easier access, DON'T lean on it.

5, To prepare the new pump, you need to twist the connectors to an angle of 45 degrees, use the needle nose pliers, this makes enough space for spade connectors.

6, Attach 6" of cable to each spade connector, and then connect them to the new pump, make a note of +ve & -ve terminals. At this stage you can test new pump by connecting cables across battery for a couple of seconds. You can if you like, use insulation tape to secure wires to pump, I haven't found that necessary.

7, To remove old pump, disconnect the electrical connector.

8, Using pipe clip tool, move the pipe clips a few inches away from pump, this will cause grazed knuckles and induce a huge amount of cursinghttp://www.fordgalaxy.org.uk/ford/public/style_emoticons/default/laugh.gif more so with normal pliers.

9, Using a twisting action remove the pipes from the pump, there will be a small loss of coolant, but nothing to worry about.

10, You can then either slide the pump out of it's rubber rings or wait till you...

11, remove the mounting plate, x2 10mm bolts, and then remove the old pump.

12, Cut off the nearside rubber ring from the plate.

13, I sliced the o/s ring and mounted the new pump (larger diameter) inside it using a not so modest amount of tie wraps, ensure the outlet is pointing down.

14, For the the electrical connection, you can either, skotchlok in to the existing wires without the need to remove the original connector, if your doing it this way expose the 2 wires from the protective plastic, wait till after you've refiited the pipework to make the connection. OR you can remove the connector and stick a block connector in it's place, if you're doing it this way do so now, open the terminals for the pump side of the wiring, and wait till the pipework is done before connecting pump. If your really clever you can source the proper connector.

15, Remount the pump & bracket assembly, taking care not to knock the wires out.

16, Re-connect the pipework. again avoid detaching wires.

17, Connect the wiring, this is very fiddly, trying to work behind the expansion bottle, make sure the +ve from the pump goes to the GREEN wire.

18, Re-connect turbo pipe and fuel filter.

19, To prime all I needed to do was squeeze the inlet pipe a few times

20, Test by briefly turning ign to on, don't start engine, then switch off, pump should run for a 2/3 minutes, check for leaks, you may hear air pass through pump for a while this is normal, especially if you old one hasn't run for a while. If it screeches this means it's not primed, give the pipes another good squeezehttp://www.fordgalaxy.org.uk/ford/public/style_emoticons/default/wub.gif

21, Refit scuttle tray and engine cover.

22, Run engine till hot, if it's cold enough outside your aux heater should fire up and (except for glow plug and other faults) run properly, there may be a lot of smokehttp://www.fordgalaxy.org.uk/ford/public/style_emoticons/default/laugh.gif, check for leaks, and check coolant level.

 

Job Done.

[NikpV]

Some pictures from 2.3 version here

[MadBaz]

Some pictures from 2.3 version here

 

Good piccys, good idea siliconeing wires in, why didn't I think of thathttp://www.fordgalaxy.org.uk/ford/public/style_emoticons/default/ph34r.gif.