Lotus TWIN-CAM Water Pump Replacement

How to remove the old water pump and install the new one in a Lotus Twin-Cam engine

[@kjellawk]

I remember that clip being a pain getting placed roperly. But my greatest problem was to get the outer impeller housing (the part with the two o-rings) in place without either a large vice or a proper press. I actually got it askew and managed to break the housing, and had to get a second kit (had to send a friend in to buy it because I felt so embarrassed going back to the Lotus dealer for another one). All in all, watching this after many years I can now feel amazed that I managed to get the engine up and running again, working in a barn without even a proper work bench. I believe, reflecting on it all, that it pays to construct simple tools for many of these steps, instead of using pieces of wood or metal just lying around. But to do that, you need a lathe and perhaps a milling machine....

[@bob1947essex]

I've found the font cover housing gets corroded. I had to machine mine out and fit an aluminum sleeve to bring it back to a standard size so that the O rings would seal properly. Hitting the front cover with a hammer is liable to break/crack it. Pressing it in is much better. The Burton version is much better.

[@markoldham5403]

That was a struggle. I'm sure you saw on editing; a camera placed on the same surface you are hammering creates difficult viewing later. I look forward to the next installment.

[@brianclaridge7695]

Fitted the Burton removable module front cover to mine, expensive but does save a lot of work when the pump bearing goes. I must say the front cover is quite delicate and would recommend using a press or large vice instead of a hammer to do this job.

[@melvinplant8637]

If he doesnt know how it goes back together, he should not have taken it apart, if you dont know what you are doing, you can end up in a world of pain, get someone who knows what they are doing, i would not let him work on mine,

[@mikemccarthy1398]

You did put the mechanical seal in correct way, only watch out is the faces can chip easily on the carbon face, hammering the impeller home might have damaged it hopefully not would have been better to press it home or squeezing with clamp.

[@melvynwoodman5787]

Personally I would not consider refitting the original spec pump having gone to the trouble of removing engine (essential for this stupid design) I would install the Burton or Dave Bean front covers with modular pump that’s serviceable in the car. Not cheap but for a long term ownership car it makes sense imo.

[@stuartclague3914]

Did you consider using the Dave Bean Engineering replacement kit? It appears to be a more durable replacement and easier to install.

[@michaelcole7659]

What temperature was the oven set to when you heated up the casting?

[@alunbrindle694]

Seems a little agricultural on the way but seemed to end in the right place.