Just obtained 1980 and am currently going through her for routine maintenace. I have no idea what/when the P.O. did. Removed the T-belt and tensioner (will be rebuilding). Removed all the waterpump bolts (11 of them), not sure if one or two is missing. I utilized the cardboard techniqe for bolt storage. I can not get the waterpump off. I've tried light rapping with the wooden portion of the hammer, but this thing will not budge. Keep wiggling by hand?

P.S., don't have the manuals yet, they are on backorder.

 

Don't recall the count and can't tell from my references.

I'd take a good look at the new waterpump or gasket. Make sure all the bolts are out. I would then apply progressively more force and maybe a sharp wood chisel into the gap. And yes, the aluminum block is really soft compared to a steel one, so going easy and smart is required.

 

Verify the correct number of bolts. I can't remember how many right now.

After all the bolts were out, I used a 2x4, about 2' long. Placed one end of the 2x4 on the on the pump and hit the other end of the 2x4 with a hammer. I had to give it several good whacks with a heavy hammer before it came loose.

Not graceful, but it worked.

 

Just counted the bolt holes from the waterpump I removed 2 weeks ago from my 79. I count 14 bolts. I had the same initial problem...waterpump would not budge...until I calmed down and double checked, seems I forgot the center bolt, hidden back underneath the top flat part of the pump! Look back in there, maybe you forgot one....the pump should come off with average coaxing...mine was the original pump from 1979 with 107,000 miles on it, came right off when I removed that last bolt.

Good luck,

Rich.

 

Thanks Richard S. I forgot the same bolt. Looks like somewhere along the line, the P.O. only decided to put 12 bolts in, or 2 fell out.

On to tackle the seals. Hope I can look to you in future, since we have the same 80 5 sd.

 

My memory is fading but as I recall at least 1 of the bolts is also for the belt cover. There are a couple that are hard to see, check the new pump and be sure you removed them all. Mine came off with just a light tap with a rubber mallet.

I had 2 bolts break when replacing them, even with proper torque. beware of this they are a b!tch to get out when broken, not a lot of room.

hth

 

Yep, as Mitch said, at least one bolt is for the plastic belt cover...forgot about that.

Rez...Glad you were able to get the waterpump off with-out any damage. I broke off 2 bolt heads and had do drill the remaining pieces out...they wouldn't budge, I tried easy-outs and reverse drill bits. Finally just drilled the whole bolt out and re-threaded the hole with heli-coils. Bought all new bolts, and resealed the waterpump gasket with Yamabond 4.

Also, be aware of the different length bolts and where they properly fit. I initially bought all bolts the same size, only to make another trip to OSH for a few shorter ones.

Let us know if you need any other advice.

Good luck,

Rich.

 

I cannot remember who posted this originally, but here is a reference I used when doing my waterpump earlier this year. I found it invaluable for reassembly.

It denotes the bolt length in addition to position. Total of 14 bolts, as I count them. I just printed this out roughly life-size, stuck it to a piece of cardboard and then inserted the bolts in the correct positions as they were removed.

Though I would pass it along for future reference.

Regards,
SteveCo in St. John's

 

Great pic (and idea) SteveCo. You also helped me confirm which bolts were missing too.

 

Steve,
Done by a fellow Newfie b'y. Glad you found it helpful.
Remember, all the bolts stick out the back of the pump exactly the same distance.

 

Good info to have, makes life easier for sure! I think the hole marked "L" below the right side "PIN" hole is the hole for the plastic cover bolt.

Rich

 

Here is a link to and findings from that earlier post:

https://rennlist.com/forums/showthre...highlight=26mm

Water-pump bolt configuration:

There's been so much talk about this that I thought this picture should be a separate, searchable post. All bolts are 10mm (#6) S = short (20mm thread length) L = long (26mm thread length).

--------------------
1991 GT Blk/Cashmere, RMB, Autothority

The bolt position marked "S" directly to the right of the pulley was the longest bolt that was put on through the center belt cover on my 86.5 I believe. YMMV

Troy
86.5 A/T Euro 5L

According to the workshop manual(pg 15-13), the longer bolts are M6 x 25 and the shorter ones are M6 x 20. Interestingly, the workshop manual only lists 5 shorter and 8 longer bolts, although the 14th bolt is shown on the picture, it is not numbered nor listed. It is actually the 9th M6 x 25, and I think it penetrates the water jacket.

--------------------
Mike S4
1988 928S4 5 Speed

Richard has a legitimate question - one of the water pump bolts penetrates the water passage, and the FWSM says to install bolt 14a, M8x62 using Loctite 574.

Tensioner Bolt:
On page 15-10 of the manual it shows the item # 14, the lower bolt on the tensioner, as being a 62mm long #8 bolt. On my car the bolt is 80mm long and a 62mm long bolt bottoms out before the threads touch the back. Is this a mistake in the manual?

--------------------
1991 GT Blk/Cashmere, RMB, Autothority

PET indicates the lower bolt is 8 x 62 mm and the upper bolt left side a 8 x 45 mm.