Boxster Can't Hand-Turn New Water Pump Installed

[JNC123]

My 1999 Boxster (90K miles) started leaking massive amounts of engine coolant. I removed the old water pump - WP (had plastic impellers and was original since metal gasket had to be cut) which had a failed shaft bearing determined by excessive shaft play once removed.

I ordered an Ebay replacement water pump (Parts Master - China) that came with metal impellers. The replacement water pump fit up very well to the bolt holes and block and seemed identical to the old pump (except difference of impellers stated above). However after installing the new WP twice without the belt installed, the new metal impellers were striking the engine block, thus not allowing hand-turning of the WP, from one impeller to the next. I inspected the old plastic WP impellers and noticed that they had some wear mainly across the top of the impellers, but also some on the ends, although none were broken or mangled, only smooth wear. I also noticed some some smooth black plastic marks across approximately one/half of the round opening on the engine block where the old plastic impellers apparently wore some onto the block over time or maybe from WP bearing failure.

After the new WP was removed after twice installing, I noticed scuff marks on the ends of several of the metal impellers from my attempting to hand-turn the installed new WP. I also noticed scuff marks on the engine block from the attempted hand-turns where the 2 flow seal 'posts' are located on the block.

Question: Do you think that a slight filing the ends of the new metal impellers, until I can hand turn the water pump installed, without any restrictions, will correct this problem? I don't want to deposit metal filings into the coolant system, causing engine failure as I have read about here.

Also, given the time I've spent resolving this, I've forgot where the 2 long WP bolts (out of the 7 total) go back...I think they go into the holes where the WP bolt holes has ferule extending out of 2 of the WP holes?

[feelyx]

Personally, I would get another one, but I would guess without seeing the fitment, that you could try and press the impeller farther on the shaft. Do you know if the belt side lines up with the other pulleys?

[JFP in PA]

You just discovered why you should not buy stuff like water pumps based upon price alone; you typically get what you paid for…… Rather than fuss with the knock off pump, I would either return it, or throw it in the trash. We have never had any luck with aftermarket water pumps on these cars, and the ones with metal impellers can chew the Hell out of your engine case when they fail, filling the cooling system with metal filings. Not a good thing on an engine with a lot of very small water passages……….. Buy an OEM unit.

[jimcg]

Had the same issue with a non OEM pump and went down the route of filing the tips of the impellers. I marked the ends of the impellers with a felt tip pen and test fitted and rotated by hand and then simply removed the high spots. Sounds a bit of a rough solution to some but it's pretty basic mechanical fitting skills. That was a couple of years and ten thousand miles ago so it's either fine or of if the doom merchants are correct I am heading towards a catastrophe.

[randy_k]

Just curious. How much less was the aftermarket pump than the OEM?

Randy

[JNC123]

Thanks for the advice for which I will heed. My Chinese water pump was $100, Porshe dealer wanted $640. Will try to find an OEM pump and order it today......Thanks all!

[Meirschwartz]

i got my pump (a year ago) from Suncoast parts for 268 + shipping:
Water Pump with Gasket:Porsche Parts & Porsche Accessories - Wholesale Porsche Parts & Tequipment - Cayman Panamera Cayenn
try also sunset parts. they might give you even a better price.

[Harriet03]

Thanks all!

[steveng1993]

Pelican sells OEM pumps for 276.
That's where I put my money.