Hi,

I have a 1987 240. Water pump started leaking so I thought I'd replace. Everything's out. Got the pump on the 2 bolts with screws loosely on. Can't get the 3 bolts to align. I took the big mushroom gasket off and tried to align without the gasket just to see how much I'd have to scrunche it. Looks like I'd have to really apply some serious torque to get it up into the cylinder head. Could I have the wrong water pump? I mean, I know the seal has to be tight, but I think I'd have to apply so much pressure, I'd cut into the seal.

Thanks,

OregonVolvo

As a rule whenever doing water pumps I go to the grinder and taper the bolts about 1/4" and then hit them with the wire wheel,after that they just seem to find the hole with nearly no frustration.

I use a drift pin punch in the lower hole and lift to align the bolts. A smooth round screw driver shaft would work as well. Be careful not to damage the threads as you lift/lever the pump into position. I almost lost my mind until I was told to try this. I changed two pumps in a row with no problems.

With no gasket on. no top seal, on etc. put the pump on the two studs with no nuts and make sure you can slide the pump up to where there is no gap between it and the bottom of the head. If something stops it from sliding all the way up, you may have to clean out the bolt holes with a rat tail file. I've seen some pretty sloppy castings on some of the aftermarket pumps.

I have used a piece of 2X4 lumber to pry the waterpump back and compress the rubber gasket. Tore one up once and had to buy a whole new waterpump because gasket was not available by itself (so be careful). (This was an emergency roadside repair)

I hearing you talk about two things.

-You can't get the 3rd bolt through the hole (to align).
Check against old water pump, do you have the right one?

-The gasket is too thick to thread the third bolt (which I have to wonder why the other two went on).
Did you clean the old gasket off?

You know about pushing up on the water pump as you snug up the bolts?

Also suggest you line the gasket up on the block and make sure the holes line up. Then do the same on the pump. If the gasket does not line up on both, something is amiss.

I use a thin coating of Permatex water gasket and stick the gasket on the block. Also apply a very thin film to the face of the water pump. Install the top doughnut gasket and then guide it up on the block stud. Put the heater tube gasket on the tube, not in the water pump and ease that up in the pump. Start a nut on the top side and then one one the bottom, leave plenty of slack for now. Then you start the bolts and nuts around the pump.

The next key is to push up with a good force as you tighten up the nuts and bolts. If you are a one man team take a thin stick and cut a V in one end. Put that V right behind the fly wheel and raise the jack until you see the water pump get snug. Does not require a lot of pressure to do this at all. I leave the wood block snug until all of the bolts except the heater tube are snug. That is the last thing I tighten up. Slip your two water pump belts onto the pulley before you push it into place to save yourself some prying and pushing.

Regards,

Paul