Date:         Fri, 13 Jun 2003 07:01:07 -0500
Reply-To:     Chuck Hill <hilltech@NETINS.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Chuck Hill <hilltech@NETINS.NET>
Subject:      Water pump removal
Comments: To: "sam.cooks" <sam.cooks@verizon.net>
Content-Type: text/plain; charset=us-ascii

Sam writes:

I have been proceeding relatively well with the removal of my water pump
until just a few minutes ago.  The right Allen head bolt that hold the
pipe that carries coolant to the right cylinder head is stuck and I am
pretty sure the Allen hexagon has stripped.  (The head slips to the next
position when substantial force is applied.  Only did it twice.)  Yes,
the one almost hidden behind the crank pulley, which I have not
removed.
....

Can I get the pump out with this pipe still attached if I disconnect the
pipe from the hose that goes to the right head?  Any other solutions,
fixes, suggestions for doing it without having to remove the big pulley
or is that now my only route to completion?

Sam, leave the big pulley alone.  I don't think you'll have much luck
removing it anyway.  Keep working on the allen head bolt.  Soak the area
with a solvent overnight.  Try tightening up the fit of the allen head
by tapping at it with a long straight punch.  Try loosening it in the
threads by tapping, tapping, tapping at it straight on the head with a
flat head punch.  If all else fails try cutting off the head of the
allen bolt with your Dremel tool.  If that fails, and you have all the
bolts out of the pump, try removing the pump and pipe together.  See
page 19.14 in Bently.  There is a clamp on the rubber pipe that joins
the two steel pipes that doesn't show, but must be removed.

You should also have the water pump drive pulley halves off and out of
the way to do this.

Good luck!  Ah the joys of working with old stuff!

Chuck Hill