Water Pump REMOVAL 2.1DJ

[Proker911]

Dear Syncro - nuts!
Understand the devotion - owned my 1990 Reimo hightop syncro camper since 1993 - THIRD ENGINE, WELL OVER 200,000 MILES! most unreliable thing on the road but I LOVE IT

Question: I have 2.1 DJ engine - had water leak at join between Water pump and block - have removed all attachments- pipes etc undone pump, now clewar and free, but bottom water hose(solid) going to right hand bank behind crankshaft pully! STOPS removal- Do I have to remove crankshaft pulley - if so HOW I have no access for a big socket (torque setting is 230 LbFt so spanner is not going to work)?

[Jim Hunter]

It can be removed with the pulley still in place.It requires a long or a T shaped allen 6mm to undo the two bolts that secure the pipe to the pump..

[Proker911]

Thanks for replying Jim
I had already undone both the water pipes (right & Left)mounted with the Allen bolts and the three nuts holding the water pump, its free and I can move it - my problem is that (looking at the pump from the rear of the van ) the right hand water pipe is a solid pipe that goes behind the crankshaft pulley, and that pipe is in the way when I try to withdraw the pump off the studs. That pipe goes to the right hand block - there is a small rubber connection half way along but that is totally inaccessible with the engine in situ. Any ideas?

Thanks
Mark

[KarlT]

It should be possible. A big screwdriver/bar to lever pipe back. Its tight, but unless you've had bigger studs fitted it should come out.
Getting it back in is even more fun

[Syncrobaz]

I undid my pulley bolt using a combination spanner and my trusty "persuader", makes it much easier to change the pump and exposes the oil pressure switch which I changed to prevent the "buzzer of doom" syndrome !!!!

[Jim Hunter]

I am glad that you have sort it out
Also is a good idea to check the short rubber connection for wear too ?

Jim

[m3nutter]

i think i did that once with an allen key with the end sawn off - so the short part of the "L" was shorter

[Proker911]

ITS OUT ! thanks everyone could not have done it without your ideas and support.

If anyone else finds a water leak around the water pump - here is what I have learned. It might save you a couple of hours/days!!

1) To get the water pump off you I had to either remove crankshaft pulley (NOT EASY ) or the little length of hose on the right hand pipe going from the water pump to the head on the other side. To do that I had to remove the alternator mount, dip stick tube, power steering mount, I had to drop the exhaust heat shield because the clamps on the connecting hose had been put on from underneath when the engine was built (by me!!) on the bench. Once I had short hose off the solid pipes they overlapped and allowed the water pump to come off its studs. If you want to see a picture send me a PM and i'll email it. When you put the little connecting pipe back make sure you can access the clips from the top!!!!!

2) The supply feed to the oil cooler behind the filter has to be removed in order to access the bottom left water pump bolt.

AND MOST IMPORTANTLY The water supply and return feed tubes on the oil cooler are made of a material that oxidises between the pipe and the rubber hose - causing it to bubble and this causes them to weep/leak as the pipe can't make an effective seal. AND THIS COULD HAVE BEEN THE PROBLEM ALL ALONG - PERHAPS THE PUMP DID NOT NEED TO COME OFF!!!!!!!!!!!!!!!!

THANKS FOR BEING OUT THERE

Mark