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Completed water pump - Thanks! (long)
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Posted by Harold [Email] (more from Harold) on Mon, 26 Mar 2001 17:26:01 Share Post by Email
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Done with the water pump and as of this morning no leaks. In general it went OK but I made some mistakes and took a lot longer than I thought I needed. Basically, the removal of the pump went very well, got it out of there in less than one hour. From all the posts, I decided to try to not move the AC compressor. Made two mistakes. My mechanic suggested to warm up the car slightly so the old packing would come off easier. I thought about that after I removed all the belts. Second mistake, the car had been leaking a lot since Tuesday so I figured all the coolant at the pump was gone. There was a lot more when I took the pump of. So the grass along my driveway is a little greener now. One thing that worked well was to mark the position of the nuts used to tighten the belts with whiteout so I can set the belts at the same tension during the re-installation.

The first main challenge was to remove the old packing. Most of it stayed on the car. I had somebody to hold the mirror and I had a pretty good view. It just took a very long time to clean it up. Used a razor blade and a scrub sponge. It just was taking forever and I was still not happy with the result. So I ended up using 230 waterproof sandpaper with lots of water and putting very light pressure on it. Got rid of all the old packing. Since I had used the sandpaper, I decided to use the Loctite 518 for extra sealing. Made the installation of the pump with the gasket a little more difficult. That's when I really messed up (third mistake). Since the installation is all by feel, I cross-treaded on of the shorter bolts. It was going in partially, but difficult. Did not like it so took it all out again. Found a piece of thread on the bolt so I knew I was in trouble. Back to the car place trying to find a metric tap set to clean up the tread. Since only the first part of the thread was damaged, the bolt goes in there about an inch deep, and you only tighten the bolts at about 20 feet lbs (200 inch lbs) I figured I could save it. To make sure that the tap was going in straight, I decided to move the AC compressor. The 6 mm hex bolts on top were really tight and hard to get to. The feared 12 mm bolt on the bottom of the bracket was a piece of cake. When the alternator is out of the way (towards the fender), you have good access to the bolt with a simple box end wrench. Just kept the end of the wrench pointing towards the back of the car, below the alternator guide bracket.

With the AC compressor out of the way, the rest was easy. Cleaned the thread, got new Loctite 518 on the surfaces. So nice to be able to see the surface directly! It's ironic that I spend so much time messing with the mirror trying to avoid moving the compressor because it sounded so difficult and because I was trying to save my AC hoses. In the end, had to do it anyway.

So far no leaks, so I'm crossing my fingers. Read another response to one of my earlier posts suggesting blue Loctite for the four 10 mm bolts on the pulley. Will probably take those out one by one to add the Loctite. I guess it would be a little messy if that one came loose. Also, from suggestions on the bulletin board, also tried to replace some of the top hoses. I think that would be an excellent thing to try and break the Saab continuum. They looked OK on the car but showed a significant bulge when I took them off. I wasted a lot of time running around to different part places but could not find anything meeting my standards. So I put the old stuff back and will put in a mail order to be done at a later date. At least, I only have to drain very little coolant for these top hoses and thermostats.

In summary, not a bad job. I think my advice would be to move the AC compressor. Just loosened the mounting plate and moved it one inch to the front of the car. Just enough to be able to see the surface of the mounting area on the engine.

Again, thank you all so much for your advice. I should get my new center muffler in later this week so that will be my next project to get rid of this annoying rattle from a loose flange in the muffler.

Harold
89 900 133k
91 900 141k
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