Quote:
Originally Posted by CT Jack
...The biggest variable I have found is with the outside shape of the pump castings where they enter the ID of the Al fan pulley. The pump castings were made by numerous suppliers. As a result there was no dimensional control over the outside shape. If there's an interference between the pump casting and the pulley ID the pump can be belt sanded to provide the necessary cleance.
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I second this, I've found this issue with the last four water pumps I've worked on, including a brand new "leakless" from one of the major vendors. You can hand sand or file it to fit, but I made a jig so I can put an intact pump, shaft or not, into my small lathe and turn down the nose. I find a diameter of about 1.63" (a hair over 1-5/8") works fine. Interestingly enough, I also find that when I turn to this diameter often not all of the nose of the pump is touched by the lathe tool, indicating that the opening is not centered exactly in the nose casting. What's important is that the bore of the nose is collinear with the bore at the rear, and that center axis of these bores is perpendicular to the mounting surface.