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    Thread: Why the secondary / auxiliary / after-run water pump stops working and what you can do to fix it

    1. 04-28-2008 06:19 PM #71
      ok, after checking NAPA, CarQuest, AutoZone, Advance, Lowes, Homedepot. I finally found it and fixed the problem!

      Ace Hardware has the O-ring for .49 plus tax.


    2. Member rigger's Avatar
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      11-17-2008 10:28 PM #72
      just wanted to add a little diagnostic help here:

      1.
      Remove the connector from the aux water pump

      2.
      Turn on the ignition.

      3.
      If you check the voltage with a digital voltmeter, you will see no voltage

      4.
      If you have a 'max' (peak) feature on the digital voltmeter, select that, then you will see it blip to 11v or 12v every 10-15 seconds.

      It seems that the controller detects that there is no water pump attached and shuts off the 12v supply. This caused me grief so I thought I'd share.

      You can get around the fan controller shutting off the power by rigging in a brake light or turn signal light bulb into the circuit to give it something to detect as a load.
      (or just using that light as a tester in the first place, sometimes it's better to keep it simple and go oldschool.)


      BTW, it seems that the fan controller keeps 12v to the aux pump after the ignition is off and does not do this 'detection' routine, but only if there was a load when the ignition shut off...


    3. Member rigger's Avatar
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      11-21-2008 12:06 PM #73
      Did anyone find any brush replacements that work??

      I opened up my pump and all that is wrong with it is the brushes...


      thanks!
      Jeff.


    4. 11-21-2008 12:56 PM #74
      Quote, originally posted by 93SLCyasee »
      My pump currently started to sound like its gargling rocks. Gonna follow this DIY and clean it out as well.

      damn so thats what that noise is on that side. it seems to minimalize when i step on the clutch though. i geuss the impellar is whats making the squeakin noise also. i just replaced the main water pump a couple months ago.

      200k on the car.

      does it have anything to do with the clutch? cause when i step on the rock in a can sound goes away? is the clutch signaling pressure to the pump? the sound is right at that pump.

      can i run the car and pull the power supply to the sec. water pump for a minute to see if that is really where the noise is coming from?

      car has been making that noise for far to long... i always thought it was the chain guides.. go figure..


    5. Member rigger's Avatar
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      11-21-2008 11:39 PM #75
      Ok, I found some brushes that are almost exact matches. The only caviat is that the wire comes off the end instead of the top. I have a set and will try them out when my brushes totally die.

      check it out:
      RC Car brush: P94
      http://www3.towerhobbies.com/c...6&P=V
      INCLUDES: Two Epic P-94 brushes
      SPECS:
      Length: 7/16" (10mm)
      Width: 3/16" (5mm)
      Height: 3/16" (5mm)

      BTW, they were only $6 canadian... And less online


    6. 01-02-2009 01:21 PM #76

    7. Member demented_irony's Avatar
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      01-26-2009 05:49 PM #77
      I received my two sets of the EPIC EP1200 P94-style brushes the other day and installed them into my auxiliary water pump. Holy crap what a nuisance installing the brushes is! They seem to be an exact match to the original brushes (5x5x10mm). Perhaps being a little longer (15mm?) would be best for optimal length of life. Upon connecting the pump to my power supply, it spun up instantly, and rather noisily; then quieted down to near silence after about 2 minutes. I guess the commutator had to seat itself in the brushes.

      After installing the pump back into my VR6 and jiggle around the connector numerous times, it still works perfectly and moves a healthy amount of coolant around - quite a bit actually.

      So to all those with non-working auxiliary water pumps, purchase a set of EPIC EP1200 P94-style brushes. I got both my sets shipped to me for $10 Canadian.

      Pic of the brushes:





      Modified by demented_irony at 10:28 PM 1-26-2009


    8. 03-28-2009 11:06 PM #78
      I remembered this article and was trying to search for it using "auxiliary water pump". I did not find it: you misspelled auxiliary!

    9. 03-29-2009 12:22 AM #79
      LOL. I hadn't noticed that. Fixed it.

    10. 05-28-2009 10:20 PM #80
      This probably a stupid question but, did you clip the ends off? The reason I ask is because they have discontinued this version and have one that says p94 style which does not have the end but still has the same dimensions. The part number is EP1200NT and stock number is LXEWV7.

      thanks,
      Don


    11. 06-23-2009 09:32 PM #81
      About 5000 miles ago I noticed my secondary aux pump wasn't working so one Sunday morning I decided to remove it and tinker with it.

      When I began to remove the bottom hose, the impeller housing crumbled in my hand rendering it completely useless. Frustrated because I could not find a repair kit or a pump on a Sunday, I decided to temporarily bypass the aux pump with a $2.00 coupler. This fix was supposed to be for one week at the most but because of time and money it's been a 5k mile fix.
      There are no leaks and the car has not overheated, so I'm pleased.

      I'm curious to know if anyone has done this before and with what outcome.


    12. Member Rapid Decompression's Avatar
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      06-23-2009 11:31 PM #82
      Quote, originally posted by qbancoffee »
      About 5000 miles ago I noticed my secondary aux pump wasn't working so one Sunday morning I decided to remove it and tinker with it.

      When I began to remove the bottom hose, the impeller housing crumbled in my hand rendering it completely useless. Frustrated because I could not find a repair kit or a pump on a Sunday, I decided to temporarily bypass the aux pump with a $2.00 coupler. This fix was supposed to be for one week at the most but because of time and money it's been a 5k mile fix.
      There are no leaks and the car has not overheated, so I'm pleased.

      I'm curious to know if anyone has done this before and with what outcome.

      I am sure the reprocutions of such actions would not be noticed for some time. I am sure it is to prevent a long term problem. VW put these on for a reason.


      Modified by Badboyr66 at 8:32 PM 6-23-2009

      Quote Originally Posted by skin1488760
      i am a ****ing racist!

      SCAMMER skin1488760 Christopher Heiser Escondido Ca951-756-5977 .http://forums.vwvortex.com/showthrea...4-looks-SO-CALhttp://forums.vwvortex.com/showthrea...e-intake-socal

    13. Member cgeromi's Avatar
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      06-24-2009 12:04 AM #83
      Quote, originally posted by strayjj »
      ok, after checking NAPA, CarQuest, AutoZone, Advance, Lowes, Homedepot. I finally found it and fixed the problem!

      Ace Hardware has the O-ring for .49 plus tax.

      What is the size or part # of that o-ring by chance...


    14. Member TRUEBELIEVER's Avatar
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      06-24-2009 09:10 AM #84
      Quote, originally posted by Badboyr66 »

      I am sure the reprocutions of such actions would not be noticed for some time. I am sure it is to prevent a long term problem. VW put these on for a reason.


      Modified by Badboyr66 at 8:32 PM 6-23-2009

      If you have ever noticed, vw actually puts lots of parts on for no reason.

      The word "MINT" by vortex standards means only one of the wheels has curb rash, and only one of the tires is usable.

      I BUY ALL SUPER NINTENDO RELATED ITEMS, PLEASE PM ME IF YOU WANNA GET RID OF THEM AND MAKE SOME LOOT, THANKS!

    15. 06-24-2009 09:31 AM #85
      LOL after all this time I've never see this post.

      I'll be doing a cleaning soon. I'm not at my car, but I think I have the newer model pump without the tabs on the very first page, mine's bolted. should be easier

      another great post by VgRt6


    16. Junior Member lovr6's Avatar
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      07-30-2009 12:38 AM #86
      Mine is all the contrary..,, i just changed the Fan control module cause wasnt switching the fans on,.. everything is fine now but the electric water pump it wont shut off!!,. i also replaced the temp sensor on the head for a new one , but still running and draining my battery even runs in cold,. everytime. anytime all the time

      what may be telling the fan control module to keep it on??


    17. Junior Member lovr6's Avatar
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      07-30-2009 12:39 AM #87
      bump

    18. 08-05-2009 09:28 PM #88
      The EPIC P-94 brushes may have been discontinued and seem to be hard to find. I just bought a set from RCPROCENTER.COM for $2.81 plus $1.99 shipping. Not bad. The link is - http://www.rcprocenter.net/ser...etail.

      I'll post if they work.


    19. 08-08-2009 03:06 PM #89
      The EPIC brushes worked great. The pump runs as strong as ever. I'll add pics to the original post to show how to replace the brushes.

    20. 08-14-2009 07:19 PM #90
      Gary, this is the third writeup you've done that has helped me tremendously with my 01 VR6 GTI. Just did the cleaning procedure last weekend and it worked perfectly. Plenty of life left on the brushes, just caked full of dirt and was only working sporadically. Works perfectly now!

      Thank you!!


    21. 08-14-2009 08:17 PM #91

    22. 10-11-2009 08:25 PM #92
      Quote, originally posted by VgRt6 »
      The EPIC P-94 brushes may have been discontinued and seem to be hard to find. I just bought a set from RCPROCENTER.COM for $2.81 plus $1.99 shipping. Not bad. The link is - http://www.rcprocenter.net/ser...etail.

      I'll post if they work.

      can you please post those pics. thanks


    23. 10-11-2009 08:47 PM #93
      I'll have to find where I put them. The replacement procedure is pretty self explanatory. Unsolder the old brushes, solder the new ones.

    24. 10-12-2009 05:44 PM #94
      so i pulled the pump, applied 12v to it and i can feel it running. not strong but runs. so i then measured the voltage across the plug connector and most of the time i get about .368v ok so what the hell. i looked at the cables/wires and they look ok. what else can be wrong? i pulled fuse 16 which is a 10A fuse and both my fans turn on. i believed my AC is still good; i can test it when it's not so cold out to confirm. is there a way that i can test the actual switch? i forgot the name but i read that it controls both the fans, ac clutch and this after run coolant pump.

      by the way, this is on a Audi TT 225 but i don't think it's much different then the Jetta. any help is greatly appreciated.


    25. Member VR6TUNER's Avatar
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      11-24-2009 11:28 PM #95
      Quote, originally posted by VgRt6 »
      The EPIC P-94 brushes may have been discontinued and seem to be hard to find. I just bought a set from RCPROCENTER.COM for $2.81 plus $1.99 shipping. Not bad. The link is - http://www.rcprocenter.net/ser...etail.

      I'll post if they work.


      The link no longer works but I was able to find them at their new address.

      Here it is:

      Trinity Epic P-94 Style Brush No Terminals EP1200NT
      http://www.rcprocenterstore.co...etail

      Not sure which ones work best so here are the other ones that are P-94 Style

      Trinity Epic P-94 Style Brush Dual Terminals EP1200
      http://www.rcprocenterstore.co...etail

      Hopefully they won't change the URL again..


    26. 05-24-2011 06:39 AM #96
      Just did this! Thanks for another awesome write-up

    27. 10-24-2011 02:29 PM #97
      just wondering does anyone know the flow rate of this water pump in GPM?

    28. Member
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      10-24-2011 06:21 PM #98
      my brother has a 1998 Cadillac catera and his car has from what it looks like to me exact same water pump as my mk3 jetta. I will look into it and if thats a case trip to a junk yard for some extra pumps never hurts lots of cateras on a salvage yards where im from LOL Maybe this can help someone. Just my 2 cents

    29. Member
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      02-16-2012 02:33 AM #99
      I accidentally ordered the wrong aux water pump and the power harness doesnt fit. are these pumps similar enough for me to shave the sides of the connector down with a dremmel to make it fit?

    30. Semi-n00b samdog's Avatar
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      09-02-2012 01:11 AM #100
      We just repaired my son's AFP VR6 Jetta aux pump thanks to this thread.

      After 10 years and 120k miles the pump would occasionally run only when we tapped on it to dislodge the brushes. The resistance would jump around; varying from from 30 ohms to infinity.

      When we got it open, we found it full of carbon dust and the brushes jammed just out of contact with the commutator. The brushes appear to have about 3 to 4 mm of wear left. We blew the dust out, freed up the brushes and held them back with 4 lb test fishing line for reinstall.

      The pump purrs now and I noted that it is powered to run anytime the ignition is on and also for about 8 minutes afterward, in this 2000 Jetta VR6.

      A new aux pump goes for about $250+

      With this repair, our pump may run 5 more years for the total expense of a penny's worth of fishing line. Thanks VgRt6!
      Last edited by samdog; 09-02-2012 at 01:15 AM.

    31. 11-04-2012 09:56 PM #101
      Found this site this evening >> http://www.carbonbrush.com/automotivebrush.htm

      Just ordered a pair of L5-5H ($8 but $7.50 for shipping ). I'll post back how they work...

    32. Member Malkierie504's Avatar
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      11-06-2012 02:12 PM #102
      Just found this thread & shared it with my brother who has a 97 Jetta GLX with a dead auxiliary water pump. We'll be pulling it apart on his next day off when we replace his coolant hoses and main water pump. Wish us luck.

    33. Member masterqaz's Avatar
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      11-06-2012 05:19 PM #103
      Nice to sand the commutator as well. Didnt see it stated.
      Coming soon 4dr pd golf on air dipped blue with hitch racks and skid. Real work horse
      Automatic cause shifting short ratio sucks

    34. 11-10-2012 11:13 AM #104
      Quote Originally Posted by gvirta View Post
      Found this site this evening >> http://www.carbonbrush.com/automotivebrush.htm

      Just ordered a pair of L5-5H ($8 but $7.50 for shipping ). I'll post back how they work...
      These brushes do indeed work, but are a tad too long. Not a big deal to file em down a little. The wire is also in the correct place. These are a pretty decent deal ($15 all-in). You could order an extra set for $7.50 more in case you screw something up or something.

      I ended up cutting the factory brush wires at the brush, then wound the wires from the new brushes around the old and soldered em together. We'll see how it holds up over time.

    35. 11-10-2012 01:52 PM #105
      I also wanted to say thanks for the fishing line idea. I was able to get it together on the first try by putting the electrical connector on the brush holder in a vice (gently), having a helper hold the two fishing lines, then setting the motor down on top of it. I think it's easier if the whole mess with the fishing line and brushes stays still so you can keep tension on the lines more easily.

      These new brushes work perfectly (after filing for length) so go order yourself a set or two. If this job took more than an hour total I'd be surprised (just remember to take out your airbox so you can get to the pump).

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