OMFG doing the water pump 4AFC :)

[Grega]

Man
What a shit of a job.
Pics and stuff to follow ; this really is an interesting job.
INOX FTW (yes Karl)

scale of difficulty on 1 - 10, with 10 being the hardest ; I'd say about 5-6.
Its not hard, just fiddly

1. Car in garage
2. Jack front of car up, put on stands
3. Jack sump of motor up a little (block of wood) on jack
4. Undo adjusting bolts for the power steering and alternator.
5. Remove belts and move them out of the way
6. Remove the bracket for the power steering adjuster
7. Undo the thru bolt on the drivers side engine mount and jack motor up a bit. Remove the mount completely. Remember to use jack under the sump to help you
8. Jack the motor up a fair bit until u can get a ring spanner onto the water pump pulley nuts, undo all four of them. The pulley won't come off. Don't worry about it.
9. Undo the bolts holding the plastic cam belt covers on. They won't come off (yet)
10. Undo the 3 nuts holding the rocker cover on. Lift it up a bit and remove the top and middle cam belt covers
11. Undo the bolts holding water pump on.
12. Undo the 2 x 12mm bolts holding the water pipe to the back of the water pump housing (INOX FTW)
13. Pull the water pump out and install new one.

Installation is reverse of the above.
I'll take some pics and put more details around this.

[Grega]

OK
Here is the long version :

1. Put the car in the garage in case it rains.
2. Remove the shielding from under the car. There are 6 10mm screws holding the shielding on
3 Jack up the car. Support on stands under the lower crossmember. Remove the jack.
4 My motor currently looks like this :

5 Remove the air cleaner (just the top bit) and pipe to the heat shield on the exhaust manifold, the water reservoir for the washers and move that black thing (breather i think for the power steering out of the way). Remove the 4 plug leads to the plugs and loosen the 3 nuts holding the rocker cover on
7. Remove the bracket from the engine mount to the power steering bracket.

8. Jack up the motor from the bottom of the sump (with block of wood on the jack) and remove the drivers side engine mount thru bolt and the three bolts (two from underneathe, one from above) on the mount (attached to the motor). Remove the power steering and alternator belts too, Push the power steering pump back out of the way and pull the alternator forward (towards the radiator) so its out of the way)

9. Undo the 4 x 10mm bolts holding the top cam belt cover on the front of the motor and the 2 from the middle cam belt cover.
10. Fun bit

Remove the 4 x 10mm bolts that hold the pulley onto the water pump. This is a slow process. With the mount removed jack the motor up a bit so this will help. I used a ring spanner slowly to make this happen. A bit painful but u will get there. NOTE : you will not be able to remove the pulley. It comes off after. With the pulley loose remove the cam belt covers now.
11.
Undo the 3 x 12mm bolts and 4 x10mm bolts that hold the water pump on. This is a slow process especially with the silly pulley there. Remove the dipstick and place it aside for later. With the pulley on the angle ; seperate the front from the back part of the water pump and pull it out - a bit of maneuvering will see it out
12.
and

Remove the 2 x 12mm bolts from the back section of the water pump housing. I put one of the 12mm bolts in the front of the housing to hold it in place. INOX ftw on the 2 x 12mm bolts in the back housing - bastards. Use a small ratchet (1/16" i guess) to get them undone, when undone remove the whole housing
13. Clean all the gasket facers, wash done with thinner, and reassemble as a reverse to the above. NOTE : put the cam belt covers on BEFORE you put the pulley back onto the water pump. With the O rings i put a dab of RTV sealant on them to hold them in place while putting the back section back in place.

Also a good idea is to replace the alternator and power steering belts while you're at it and cam belt if you're keen

Hope this helps someone in their cause. It took me a good 8 hours today (off an on taking breaks and going to the shop)

[too_quick]

You must spread some Reputation around before giving it to Grega again.

Dam.

[Moppitt]

You must spread some Reputation around before giving it to Grega again.

Dam.

Got him for ya'

Thats a handy guide, would be good for those who are a little less certian of what to expect. It all looks near enough to the same as the 4ac to count. Incidentally mine leaked 3 times (nfi why either it stopped when i got sick of it and drove it home lol)

[IN 05 NT]

1: crack water pump pulley bolts before loosening/removig belts!....so much easier

done a few now....there great fun

[Grega]

thanks guys
IN05NT.......need to remove engine mount and jack motor up before you can do that
also, a trick i learned was to put tension on the belt (ie press on it) which will stop the pulley from spinning

yeah. great fun alright

[Grega]

oh, gives you a good chance to degrease in there too. have a gander of the shit that was caked onto the poor old 4AFC