P80 P2 Coolant pipe o-ring & install 976045 Topic is solved

[Sveedy]

Engine fired up !! Sounds great. No lifter noise at all.
However ( there's always an " however " ), I have two coolant leaks. One is at the heater hose to firewall connection ( surprise surprise ) so I'm going to gut that bastard of a design and do something rational there instead.
But the other leak is where the coolant tree pipe goes into the back of the water pump. I had a hell of a time getting that pipe to fit in and go over the internal o-ring. The new o-ring appeared smaller than the original, but I chalked that up to the age of the old one.
I don't think removing the pipe and trying again is going to yield any better results, so I'm leaning toward some sort of epoxy sealant around that joint. Anyone else replace that o-ring and have this problem ? Any suggestions on a epoxy sealant ?

[bmdubya1198]

When I was young in Taiwan we used to get worms through the faucet. This was especially shocking when washing rice with contrast and all. Water supply would get turbulent during storms. Worms are especially squeamish for me . Ants also as I was attacked and my leg was bitten all over and the swelling took sometime to subside. Both of those still make me jump but snakes has gotten better but I won't put anymore up. I do make a point to wear rain boots when I am working in the yard however. Even taking out the trash.


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Oooh, that's fun!
It's the small things like that that may slip past you that really bug me (pun maybe intended...). The larger creatures that are noticeable don't bother me as much.
Pantry moths, for example, if you've ever had to deal with those. They can slip past you if you don't check things closely. Thank goodness we knocked out that problem!

I know that it doesn't go down near the starter. It was bagged up with that engine mount bracket. The two did work together somehow.
I get how that bracket etc bolts up, but it's that little wire holder that I can't remember the placement of. It also held one or more of my vacuum lines running from the turbo.

It goes a little higher up than the starter. I remember leaving the smaller bracket off my '98 after doing some work years ago, and eventually I realized where it bolted to and replaced it. I'll see if I can find a pic.

Found a pic. Not great, but you can kinda see the bracket.

[Sveedy]

^ Yes ! That's what I was looking for.
Many thanks - now down to the shop for a couple of hours to wrap this project up.

[bmdubya1198]

Best of luck!

[bmdubya1198]

It's really common to pinch that o-ring into the back of the water pump. What I've seen recommended is to remove the water pump to ensure the o-ring seats into place without rolling the edge and pinching it.

[Sveedy]

Arggh ! Idiot design then, that I have to take apart all of the timing belt parts in order to install the coolant pipe, because of the water pump. There's something to be said about keeping these things a bit more independent.
I'm going to have to think about this one. I was thinking about trying to just remove the pipe again and just reinstalling with some gasket maker added to the mix. I guess if that doesn't work then I'll have to pull the water pump.
But all considered it was a success. Fired up on the first turn of the key ( after oil pump priming ). After 6 months, what's a few water leaks.

[bmdubya1198]

Agreed! If those are the only small issues, that’s not too bad. There’s always something!

[abscate]

It’s an order of assembly issue. I wonder if Haynes catches this.

[454cid]

Arggh ! Idiot design then, that I have to take apart all of the timing belt parts in order to install the coolant pipe, because of the water pump. There's something to be said about keeping these things a bit more independent.
I'm going to have to think about this one. I was thinking about trying to just remove the pipe again and just reinstalling with some gasket maker added to the mix. I guess if that doesn't work then I'll have to pull the water pump.
But all considered it was a success. Fired up on the first turn of the key ( after oil pump priming ). After 6 months, what's a few water leaks.

I admit, I don't know what you're talking about.... I didn't know the water pump area had any pipe in the back. However, if it's an o-ring can't you use something like silicone grease to get it to slide in place?

[Sveedy]

^ Well its a buggered up design. The coolant pipe slips into the back of the water pump housing apx 1 1/2 ". The offending o-ring sits about half way in the opening and fits into a recess. The coolant pipe is so tight that you have to push/ thread it into the opening, and as you might imagine, when it comes in contact with the o-ring it will either cut it or push it out of the way. So apparently one would have to try and guide the o-ring over the pipe by keeping it in its recess from the water pump side, maybe by using a small screwdriver. All of this would be avoided of course if there was a cast male port to attach the coolant pipe to with a coupling instead of an internal o-ring to try and slip into. Or even a flange with the o-ring set into it much like the thermostat housing.
There were certainly better options than what they came up with.