Installing water pp cover and thermostat... hints/tips

 Just had another look at your last post and I see the pic of your water pump impeller installed. The circlip is not installed correctly or it's too small in size. The 2 ears should be butted up almost against one another. Quite often when removing  circlip, they get opened up too much and they deform causing them to not completely engage in the groove. I know you installed a new clip but either it's too thick for the groove or it's too large in diameter. Better have another look

 




This is the pic straight from the FSM and cropped / exploded for better viewing . This what it should look like. Note the inner edges of the ears are parallel to each other.Sometimes what I've seen happen if the shaft is soft, as the circlip is being installed it can cut a slight burr on the edge of the circlip groove and fold it inwards then leaving the circlip not fully engaged in the shaft. If that clip pops off, the impeller will drive itself in to the housing cover, and you'll be on the side of the road calling for a tow truck.

Kawboy wrote:

 Just had another look at your last post and I see the pic of your water pump impeller installed. The circlip is not installed correctly or it's too small in size. The 2 ears should be butted up almost against one another. Quite often when removing  circlip, they get opened up too much and they deform causing them to not completely engage in the groove. I know you installed a new clip but either it's too thick for the groove or it's too large in diameter. Better have another look

 

This is the pic straight from the FSM and cropped / exploded for better viewing . This what it should look like. Note the inner edges of the ears are parallel to each other.Sometimes what I've seen happen if the shaft is soft, as the circlip is being installed it can cut a slight burr on the edge of the circlip groove and fold it inwards then leaving the circlip not fully engaged in the shaft. If that clip pops off, the impeller will drive itself in to the housing cover, and you'll be on the side of the road calling for a tow truck.

Well crap. Got everything re-assembled then read this. Sometimes truth hurts. The circlip was new from de.1300. I too looked at it and thought it was a bit 'off'. But it was secure, snapped into place, and didn't act like it wanted to jump out. I did check the groove, it's clean of burrs.

Will do the right thing and tear it down again. Crap Crap Crap.

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2023-12-03 Water Pump Final InstallAnswered my own question.First install the T-Stat and housing.Then fit the lower water pump housing.To difficult to stack the T-Stat, Spring into the hole and then start the M6' allen heads.Ready to mount.

Lubed all o-rings, new gasket, fresh RTV.

Tried and tried to position the tube by hand.. Nope.
Hated to.. but covered teeth with tape and had it.

Proudly made in the USA!

Was hoping to leave not a mark.
Left one. Oh well. It's hidden.. 

Hopefully it doesn't leak.... 

I replaced my impellor and circlip a few years ago but did take some pictures - these items were both purchased from Z1300.de so assuming the specifications of the circlip have not changed, it does look like yours may not be seated correctly - sorry!

 

Neville wrote:

I replaced my impellor and circlip a few years ago but did take some pictures - these items were both purchased from Z1300.de so assuming the specifications of the circlip have not changed, it does look like yours may not be seated correctly - sorry!

 

If I were to critique this installation Neville, I would have suspected that the right ear was hung out just a tad and I probably would have grabbed a screwdriver and a hammer and given it just a nudge to ensure that the right side of the circlip was fully engaged. And likely before I did that I may have just tapped on the impeller on the right side and seen if the circlip closed up a little more on its own. The left side of the circlip appears to be sitting deeper in the groove than the right side.

In all fairness, the angle the pic was shot on may make the circlip "appear to be" not quite in place. In any event, Don's circlip installation is suspect.

Normally, when you buy a new circlip, the ears are closed and a well fitted / installed circlip will have the ears slightly open like maybe .5mm - .8mm meaning the circlip is strangling the circlip groove and not loose enough to spin around in the groove. 

Got after it again, yesterday. 

As a side note.. about the LubriPlate. Yes, I had read the FSM which says to use coolant for the lubrication assembly medium. Then I got to thinking.. hmmm, it might be some time before I put water in the block.. that mechanical seal might just go 'dry' before rotation happens.. so I used the light water 'cream' from the LubriPlate tube. Guess I'll find out later if that was a good, bad, or horrible decision. At least the decision had <some> thought process.   

Found a 'soft-jaw' plier at Home Depot. 18 USD.
Never knew they existed!Bought a bunch of metric circlips too.

Hopefully one will be correct size.

None of the new circlips  fit.
Ended up using stock OEM <used> part. 
Inspected it, not sprung, out of shape, etc. 
Good to Go.

Gotta admint, KawBoy was right. This one fits as it should.

The brown goo is Parker O-Ring grease.

Think I've over done it with pics here..

Hopefully there it is. The final-final for real final installation?

Thanks again to KB for the thoughtful advice and help! 

Did you purchase your drain pan from Z1300.de as well? I was wondering where to get one.