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waterpump/cambelt etc replacement howto?

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Re: waterpump/cambelt etc replacement howto?

Postby Mazda Mender » Sun Mar 20, 2016 10:33 pm

sandmonster wrote:All done... got more pics to come, but here's the new housing fitted taken just before the covers etc. went back on

Now, where's that Radox...?

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Re: waterpump/cambelt etc replacement howto?

Postby sandmonster » Tue Mar 22, 2016 8:27 pm

This is the little bu88er that caused it all:

How it went...

Belts off (there's a howto on here somewhere so no need to go into detail on that) but put it in gear and crack the waterpump and crank pulley bolts before taking the belts off.
IMG_2947.jpg (1.34 MiB) Viewed 1050 times

Getting the coil pack off is a bit tricky until you get the knack of getting in there with an open ended spanner at a bit of an angle (had some practice on that - see later)
IMG_2948.jpg (1.29 MiB) Viewed 1050 times

Rocker cover off (don't laugh at the bits of paper towel stuffed in the spark plug holes - had a nightmare on a former car once when something accidentally dropped in! better safe than sorry)
IMG_2951.jpg (1.67 MiB) Viewed 1050 times

Timing marks all lined up and cams locked - not sure if this is really necessary!
IMG_2957.jpg (1.23 MiB) Viewed 1050 times
IMG_2953.jpg (1.89 MiB) Viewed 1050 times

Especially as the crank locking tool from autolink doesn't lock in the TDC position??? Worried about that and fannied about checking and rechecking TDC a few times before taking the wrenches off the cams and fitting the locking tool to undo the crank bolt...
IMG_2959.jpg (1.5 MiB) Viewed 1050 times

...before refitting it loosely and resetting everything back to TDC with the crank lock removed.

Waterpump inlet bolts are tricky to see...
IMG_2962.jpg (1.91 MiB) Viewed 1045 times

Thermostat housing, waterpump off, then decision time on the cam and crank seals, decided to go for it. Seals were very brittle and were breaking up so glad I did. In the end very carefully used a spikey hook tool to stab them (gentle taps with a hammer) and then pull them out. Crank one was the trickiest as you are working at arms length.
IMG_2964.jpg (1.52 MiB) Viewed 1045 times

IMG_2967.jpg (1.58 MiB) Viewed 1045 times

Water pump inlet (need to remember to put this in position before fitting the waterpump)...
IMG_2970.jpg (1.15 MiB) Viewed 1045 times

O-ring fitted...
IMG_2969.jpg (1.63 MiB) Viewed 1045 times

Water pump fitted (pic was taken before I realised I should have put the inlet back in place first!)...
IMG_2968.jpg (1.16 MiB) Viewed 1045 times

Stopping for tea again... ;)
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Re: waterpump/cambelt etc replacement howto?

Postby sandmonster » Thu Mar 24, 2016 8:54 am

Part II as the edit has timed out...

All new seals in and waterpump housing back on (o-ring for the waterpump housing was very slim compared to the groove, would have thought it would be a bit fatter - should have taken a pic - grr - but its too late now and it seems to hold water)
IMG_2971.jpg (1.27 MiB) Viewed 1043 times

Recheck the alignment after refitting the sprockets..
IMG_2972.jpg (983.1 KiB) Viewed 1043 times

IMG_2974.jpg (1.53 MiB) Viewed 1043 times

Belt back on...
IMG_2975.jpg (1.63 MiB) Viewed 1043 times

Difference between Mazda thermostat gasket (bottom) and the pattern part one that came with the pattern waterpump ...
IMG_2976.jpg (1.45 MiB) Viewed 1043 times

CAS off, cleaned up and refitted (panicked a bit as I thought I'd rubbed off my alignment marks getting a bit giddy with the old brake cleaner, but could just see them). The old o-ring just crumbled away and the new one was obviously much fatter and juicier. Needed a bit of heave-ho to get it back in. Pic of the attachment bolt too...
IMG_2977.jpg (1.24 MiB) Viewed 1043 times

IMG_2978.jpg (902.61 KiB) Viewed 1043 times

I forgot to take any more pics at this point.. but cleaning up the cam cover took a while as whoever had taken it off last time had used silicone seal around the whole gasket so fiddly bits of silicone to clean off. That went back on OK.
Then all pipes and hoses, got myself a set of silicone hoses and replaced most of those as we went. Was running out of time so although we tried to get the heater hoses off the clip on the inboard hose was proving a little bugger to get to even with my mate's set of fancy 'remote' hose clip pliers. so that job was left for another day.
Everything else went back on smoothly and (apart from a minor brain freeze with the spark plug leads, even after checking them against Tomm's :eek: ) she started up first time. Just a little bit of a whine from the belt, so may need to redo the tensioning if it doesn't settle down with use.

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