Time to mount waterpump, problem Papajam

[qposner]

OK, so i have three of the studs cut and removed and purchased the proper replacement bolts. Problem is I cannot get two of the bolts through the front of the pump because the pump pulley blocks them. Specifically, the holes just below the three pump input/outputs and the one at the bottom. What now?
Thanks,
Quinn

[papajam]

Put the bolts in the waterpump first and then mount the pump on the engine.
Are the bolts longer than 35mm?

[qposner]

They are 6 x 1.0 x 35mm. The problem is the space between the waterpump mounting hole and the pulley is less than this. The bolt has to go in at an angle, but it will not because the angle it too great. Does that make sense? If not, I can post a pic.

EDIT: I was able to get the two bottom holes to take the bolt, however, 35mm looks WAY to long, I could try 6x1.0x20 as you mention in a previous post. Thoughts?

However, my problem is the hole where all the ducts come out of the pump. I cannot get a bolt through there. Need I buy a new stud? If so, what size and will any good hardware stuff that carries a large selection of metric nuts/bolts/etc. suffice?

Quinn

[papajam]

Well, that's what I get for not wire brushing the stud before measuring it. The 1750 & 2l parts books list the waterpump studs as being 6x1x34; not 35mm as originally posted. The only exception to this is the stud in the 9 o'clock position, as viewed from the front of the engine, on the US version cars which is listed as 6x1x49. Is this the one you can't get the bolt thru?
Two things come to mind about the 35mm bolts being way too long. One is that perhaps the threads in the timing cover are dirty preventing the studs from going in all the way and the other is do the bolts have washers on them?

Just thought of a third thing. And this is the answer. Obviously, I haven't changed a waterpump in situ in many years so I don't recall what length bolts I used. The bolt needs to be 35mm (or 34mm) long MINUS the width of the nut and the length of the stud that is exposed past the nut! D'oh! Talk about brainfade. I'll estimate that distance to be about 10mm or so which would make the required bolt length about 25mm. I'll measure and post that length in a little bit.

Apologies for making you jump thru hoops on this; it's quite obvious I made a mistake.

[papajam]

OK. Measured from the ouside surface of the stock wave washer to the end of the stud and got about 8.6mm. So a bolt 25mm long would be the ticket. The long bolt in the 9 o'clock position would need to be 40mm long.

[qposner]

Papajam,

No worries on the lengths. You have been a huge help. I will try the 25mm lengths. However, if I go 40mm on the 9:00 stud (looking at engine and positioned in with all of the pump input/outputs), I have an even greater problem. Right now, I cannot get the 35mm bolt to enter the hole in the pump because the space between the hole and the pump pulley is so short, that the bolt cannot line up and drop through. Make sense? How tough is it to pull the pulley from the pump?

[dwc]

Hi Quinn:

I usually just pull the two bottom-most studs and replace them with bolts that are 25mm long. I also put an extra washer under each one, to prevent bottoming the bolts in the stud holes. It seems an odd coincidence, but the last two times I've done this job ('74 & '87 Spider's) that third stud you mentioned has just come out as I loosened the nut, and I was able to work it back into place with the new pump without any troubles.

Regards,

Dean
Lutz, FL
'74 & '87 Spider Veloce's

[qposner]

Thanks. I was able to get everything in by fashioning a new stud out of a 1x6x50 bolt with the head hacksawed off and high strength Locktite. Thank you to everyone for the help.