The
Water Pump - Frustration Defined
Here are the steps taken on the water pump:
1) Put the new water pump on, and thought the gasket seemed
pretty chincy, as it was just plastic. It leaked.
2) Used the same plastic gasket, this time with a coating of
black Permatex on both sides. It leaked.
3) Took the pump off and examined the pump and gastket and it
became clear why it was leaking - the gasket didn't fit the
pump.
 
4) I was in a hurry to get it back together, so I did without
the gasket and just used Permatex. It leaked.
5) I got a new gasket from NAPA and redid the thing, this time
using Permatex High Tac. It leaked. It was leaking in a new
place, around one of the bolts, so I thought maybe I needed to
tighten it. When I did, it leaked much worse, and became
appearant that the pump itself was cracked. When I tightened the
bolt, it opened the crack in the pump.
6) I bought a new pump which had a new gasket, a paper gasket.
Put it all together and its holding fine. This new pump had a
heavier casting, and the pulley mounting hub is machined the way
it should be so that you can get a socket on the cap screws that
hold the pulley on. On the other pump, the pulley mounting hub
interfered with puting a socket on the cap screws, so you had to
use an open-end wrench to tighten and loosen them. It was a
pain.
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