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

[logray]

Return the pump, get a genuine Porshce one.

I wouldn't risk having the pump damage your engine case ($5000-$10000 to replace).

[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.

[logray]

Also if the engine case does get scored or ground to hell and back, I'm not so sure a new pump would be able to perform as well, since the clearance between the impeller fins and case will have changed.

It's just really not worth the <cough> "savings".

Been there done that with a cheap aftermarket pump (fortunately with plastic blades), it leaked at the shaft after only 100 miles before I ripped it out.

If you modify your new pump, you also run the risk of making it weaker and more prone to premature failure.

The companies that sell this crap should be given a swift strike with a switch across the back.

[JNC123]

Thanks to you all for the great advice for which I will heed. Ordering a new OEM water pump today....thanks again!

[logray]

GOOD choice.

[JNC123]

I installed a Porsche OEM water pump today with ceramic impeller...fit great and turns well without any obstructions. Had bought an Autozone replacement drive belt (Dayco) which also didn't fit (too short), so from aftermarket water pump & belt drive aftermarket parts problems, decided to order a new belt from SunCoast....fit perfectly and works great. I've learned from this all the risks of using aftermarket Boxster products!

Thanks all!! This is a great website for technical support!