Not a lot has been happening recently, apart from a quick trip to Australia for the Cliffhanger 4WD comp back in May. While I was away the jobs that need to be done to various vehicles in the fleet continue to mount up and it is difficult to know where to start.
One job that I did manage to get out of the way before heading away was the water pump replacement on the Discovery V8. Straightforward job under normal circumstances but I also needed to completely flush out the cooling system after using eggs to stop the water pump from leaking in the first place. Yes, eggs and they did the job wonderfully.
The water pump starting leaking while I was at least six hours driving from home and the leak was so bad that I was losing a couple of litres of water every 30kms. Out of town there aren’t many places you can get products such as Bars Leak to try and solve the problem but eggs are easily found and were the ‘original’ stop leak product.
I used just two eggs, initially planning on trying just the yokes to start with. I successfully separated the yoke and white for the first egg but the second I missed and the whole egg went in. Oh well, time to keep moving.
Loaded with 25 litres of water in various containers I started off for the first 30- 40kms. Stopping the first time everything was OK but it took about a litre. Second stop, there was a lot of frothing and another litre required. By the time I had covered 100 odd kilometres the leak has virtually stopped but I still wasn’t chancing it and continued to check the level every 40- 50km’s and it didn’t require any more water.
Once home the eggs proved so good that it was still another month before I did get around to changing the water pump, just by topping up each time I was going somewhere.
When it came to the water pump replacement I first removed the fan and then drained the radiator before removing it to flush it out properly. With the vehicle still outside the workshop, the engine was continually flushed with the hose while running to try and get as much contaminates as possible out of the system. Once done it was then inside and the removal of the water pump began in earnest.
With the radiator out it was easy access to the water pump but first it was loosen the pulley bolts before taking off the serpentine drive belt and removing the belt tensioner. The pulley needs to come off to swap over to the new water pump, but also to get access to a couple of the bolts.
A helpful tip when removing bolts that are varying in length, such as a water pump, is to make up a cardboard template of the outline of the item and put each bolt as it is removed into the cardboard in its appropriate location. This makes it very easy to know what length bolt goes where when reassembling.
With the old water pump off, it seemed like the problem was only a leaking gasket, but as I already had the new water pump it would be changed. The mating surfaces were thoroughly scraped clean of all old gasket material ready to take the new gasket. I also used a small amount of Loctite’s Master Gasket to give a good seal before reassembly. All the bolts were wired brushed clean and given a coating of copper grease.
Once fitted the bolts were torqued to the correct specification and then the pulley, belt tensioner and drive belt could be fitted. The radiator and hoses followed and finally the fan and cowling. The coolant or antifreeze is a 50/ 50 mix and is best done in small lots of water and then coolant unless you are using a premixed coolant.
While the Discovery was in the workshop I also gave it an oil, filter and air filter change. It wasn’t due but it had done 5000kms since the last change and a lot of that had been off road in dusty and dirty conditions.
LR90 has now taken over in the workshop as it needs some on-going maintenance. When I did the CV repair earlier this year I noticed that the drop arm ball joint rubber boot is torn so the ball joint needs replacing.
It is not easy to do a repair on the drop arm in situ but it can be done, although I think I will take the easy option and replace the complete drop arm with a new one, just because there is one held in stock.
Also the new heater still hasn’t been fitted into LR90 and with the Off Limits 4WD Ice Buster event coming up soon at Waiouru I think I will be needing the heater.
Cardboard bolt template.