Water Pump Change (Part 2/3)
Page 1, 2, 3
Installation of Water Pump
1) Time to clean everything up (via Simple Green, WD40 & Carb
Cleaner) and organize all the parts. Here's what all you should have:
2) Permatex the 2 o-rings
on the suction cover (update: ended up not using the o-ring on the left side
of this picture, I just permatex'd the crap out of it.)
Note: If you have removed the timing belt it is
not necessary to put the suction cover and water pump on separately. You can
bolt the 2 together, and then bolt the assembly to the block.
3) Loosen the coolant pipe by removing the 10 or 12mm bolt shown
here, that leads from the suction cover to the thermostat housing:
4) Very carefully, place the suction cover onto the block and
into this pipe. Make sure that the o-ring that attaches to the block didn't
shift on you and that you still have some permatex back there. Secure (don't
tighten) the cover to the coolant pipe, either from up top....
5) Permatex the crap out of the water pump:
6) Very carefully, again, place the pump over the suction cover.
Secure the pump to the cover by using a couple of the 10mm bolts to hold them
together. Then line up the assembly with the block, and bolt it down with the
10mm (the longest one) and the 12mm bolts. (Note: The 10mm bolt for the assembly
is for the uppermost hole.) Tighten down everything securely, according to the
torque specs in the BGB, 9 & 11 ft-lbs I believe.
Also, don't forget to install the oil dipstick guide, since it
attaches to the water pump. Put a lil RTV on its gasket.
7) At this point I would suggest to reinstall the coolant inlet
housing onto the engine and then taking a break. This way after a couple hours
of letting the RTV cure, you can check the water pump for leaks by simply filling
the system with water. If you notice any leaks from simply filling it up, you
will not have wasted time putting everything else back together. Use the new
o-ring and gasket that came with the pump assembly when installing the inlet
housing. Also, use some RTV on the surfaces.
8) Once you are sure that the pump isn't leaking, you may continue
putting everything back on. Start with timing cover #2. Again, here are the
2 bolts that need to be replaced:
9) Next up is the AC idle pulley. Insert the bolt and it's washer
And then the pulley, 'big' washer, and the nut. Tighten the nut
down until the pulley is secure, and then make sure the hole in the bolt head
is aligned with the hole in the top of the bracket.
The red-circled hole.
Then, thread the long 15mm bolt through the idle pulley bolt.
No need to tighten it down fully, just get the threads so they atleast pass
all the way through the bolt head.
10) Next, install the water pump pulley and bolts. Don't worry
about tightening the bolts for now.
11) Install the belts. Water pump and alternator belt go on the
innermost crank pulley, then AC belt. Go ahead and tighten the AC belt, by pushing
the idle pulley up while under the car. You may need to loosen the nut a little.
I tried prying the pulley up with a big screwdriver, but the best method I found
was just by pushing it up with your free hand, and then tightening the nut down
with your other hand. Use one of them belt tensioner gauges (or index finger)
to make sure the belt isn't too loose or too tight. Get out from under the car,
and tighten down the AC idle pulley bolt (the long 15mm one).
12) Install the water inlet housing with new gaskets.
12) Re-install alternator. In the below pic, the above mentioned
AC idle pulley bolt is shown in the red square. The green arrow is pointing
to the alternator of course. If you need assistance with the alternator refer
to my alternator write-up.
13) Reinstall Timing cover #3. Again, here's a picture of it uninstalled
so u can figure out where all the bolts are located. The one in the bottom middle
is the toughest to get to.
14) Reinstall radiator cap hardware and hose. Don't forget to
reconnect those 3 wire connectors. Also ground the yellow/black wire onto the
body through one of the green circled bolts.
15) And finally, the coolant reservoir:
Goto Page 3 for the
coolant flush process...