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alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 281

110 TD5 PAS pump removal

Currently fighting with water pump replacement on my 1999 Defender TD5. Things were going well until one of the water pump housing M6 bolts sheared.

Removed the pump and am trying the put two nuts together on remaining thread to remove the bolt shank. if that doesn't work then plan is to remove the PAS from the "Bracket assembly-coolant & power assisted steering pump" and unbolt the bracket assembly from the engine.. its only 5 bolts all of which are accessible. That way I can easily use a stud extractor or helicoil it if necessary on a bench

Question is .... I *think* I can just remove the pump and leave the pipes connected then put it together again afterwards, but if I do have to remove the hoses, how do you do that? are they just push fit, they've been there for a long long time. Can't see any flat bits to put a spanner on. one has a jubilee clip on it ( don't think thats right)

Any help appreciated

Rgds
Alex Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

17th Jun 2019 3:18pm

derbywill

Member Since: 25 Mar 2010
Location: Derbyshire
Posts: 559

Hi Alex,

you can leave the pipes connected and swing it forward if this would give you enough clearance,
The pressure pipe has a hex for a spanner on it and the return just has a jubilee clip on it.

Cheers

Will 2005 90 XS
1954 86'' Series 1 tilt
1968 88” 2A 200tdi
2002 110 Hardtop

18th Jun 2019 12:06pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 281

Cool!
As long as I don't have to use a crowbar to get it out of the bracket

You wouldn't imagine a sheared M6 bolt could cause so much trouble!

Rgds
Alex Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

18th Jun 2019 12:44pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 281

o.k. next related question

Given that water pump removal necessitated use of hammer and small screwdriver followed by bigger screwdriver and finally chisel ( yes the water pump casting broke in 1 place ) I'm sort of keen to make sure that the new one can come out in 1 piece should it ever have to.

The pump has two rubber seals, one facing inwards and one outwards and then theres a gasket between it and the outside cover you attach a hose to

Is it worth putting some copper grease along the water pump face that touches the mounting bracket ? what do other people do ?

Also , whats the torque setting for the water pump cover bolts and the PAS pump to mounting brackets?

That'll do for now

Rgds
alex Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

21st Jun 2019 11:21am

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 281

Well,
Removed the pulleys o.k.,loosened off all the mounting bolts of the main water pump/PAS pump bracket ( still trying to undo the nut on the stud undone all the bolts holding the PAS to the bracket . Does feel like its permanently stuck there.

Is it really lust a case of a big hammer? crowbar to prise the pump off the bracket? Can't see anything else that might hold it in place
Don't want to even think about undoing the high pressure feed don't think it's been touched since the car was new!. Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

21st Jun 2019 9:03pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 281

And the answer is, of course, a crow bar.Pump out of housing.. now 5 bolts and a nut and the whole mounting bracket is off .....except the nut of course is a bit rounded off and currently seems to be staying put
Ho hum .. one step forward slight shuffle back. Last thing before I can start reassembling Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

22nd Jun 2019 12:25pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 281

Been a long time since I had to resort to a junior hacksaw and a lot of patience. Problem was my maplin dremmel lookalike seemed to have a bit missinbg so couldn't use the flexi coupling to get a cutting disk nears it.

PAS back in place, new water pump installed centrifugal oil filter houseing back in place along with tubev down to engine block. Ready to flush out the coolant and fil with new.

three final questions -0 torque setings for the following ?

Ancillary mpunting bracket... 5 bolts holding it to the enging block.
2 * Ancillary drive belt pulleys one with w 15mm bolt the other with 3 10mm (?) bolts

Centrifugal oil filter 3 bolts two long one short ..

The big chunky ones I've started at 30 NM Thr 10mm ones a lot less Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

24th Jun 2019 8:26am

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