Technical Water pump replacement 3 litre Ducato

[errolmorris]

Thank you Techno, that is very helpful. I have just been looking at some of the prices of parts and comparing them with here and your prices seem to be around half what they are asking in Oz. Even with our dollar in the doldrums, your prices are pretty damn good.
Thanks for that link as well. I'll do some more study this afternoon when I finish work. It's 0800 Monday 4th here, so I'd best get the shop open and earn another million.

 

[Techno100]

I have no idea what import duties are for you though. Anywhere in EU has no import duties and VAT is paid on all purchases. Perhaps you'd get a VAT exemption to offset OZ taxes??

 

[errolmorris]

Thanks mate. I hope I am able to return the favour in some way. There are a few parts that I will need shortly to replace a few bits and pieces and to carry as spares.
My van only has 107,670 kilometres but has been sitting for a long time, so I need to replace some hoses and stuff before I start any long distance running.

 

[Techno100]

Be careful with LHD & RHD parts as with some they do both like door mirrors headlights etc

 

[errolmorris]

Unless the rules have changed recently, we only pay duty on purchases over $1,000 (AU) or for commercial quantities. If we pay VAT, I think the GST is waived here. Either way, it is still far more economical to purchase from overseas. Our government is trying to increase taxes to prevent freedom of choice, so in the meantime we'll all take advantage of the situation and make our dollar go a little further.

 

[errolmorris]

Noted...thank you.

 

[adlarplant]

try using genuine iveco parts ive found them cheaper in most cases on my 2.3l

 

[Techno100]

My order arrived today
2 Gates belts, automatic tensioner and a sump pan seal £55 delivered

 

[adlarplant]

Believe it or not in Australia check out supercheap auto their website has numerous parts available for the ducatos just use the finda part section its suprising whats available Cheera Adam

 

[errolmorris]

That seems pretty good to me. My belt cost me $118.00 from a mob in Victoria and this was the best price I could find back then. I think freight was around $20.00.

 

[GMMOTOR]

This is a great place for spare OE Fiat parts, Definitely one of the cheapest suppliers i've found - https://www.onlineautomotive.co.uk/Fiat-Car-Parts.aspx

 

[cessnapilot177]

Hi, i know this post is 3 years old but i just bought an Autotrail Cheyenne 3.0D which is ducato based and at 14000mls has a leaking waterpump. the main dealer here wants around £1000 labour plus vat for the job. the ICME time is 9.65 hours. which i find difficult to take. The pump is driven by an auxiliary drive belt and fix to the block by about 5 bolts. i can see the need to remove front bumper cover and headlamp for access but Fiat and Autodata say all below is needed to do the job. ????

Autodata says the following needs to be done
Remove and Install Engine & transmission complete Remove and Install Camshaft/valve cover & gasket Renew Engine oil & filter Remove and Install Turbocharger oil feed pipe Remove and Install Alternator drive/serpentine belt Bleed Injection system Remove and Install Injection pipes (all) Remove and Install Turbocharger Drain and Refill Coolant/antifreeze Disconnect Radiator top hose Disconnect Radiator bottom hose Remove and Install Exhaust manifold Partially remove Exhaust manifold(s) Remove and Install Exhaust manifold gasket Bleed Hydraulic release system Top up Gearbox oil Check and Adjust Gear linkage Disconnect Gear linkage Disconnect Driveshaft (both) Disconnect Front suspension ball joint(s) - lower Remove and Install Wheels - (both)

My question is before i tackle the job myself or decide to give in and take it to the dealer, did you have to remove engine, turbo and top cover, or did you manage to remove and re-fit new pump in situ?? regards David

 

[whine0]

You can change the pump without taking engine out it’s tight and fiddly I don’t take engine out for pump replacement but you’ll need good trolley jack to allow movement in engine to get it out

 

[errolmorris]

G'day cessna.
The only things required is to remove the bumper bar and grill assembly along with the headlight (right side if you are sitting in the driver's seat) and a few bits around that area. Remove the radiator to avoid damaging it and it is worthwhile replacing the radiator hose and any other hoses you can see at the front of the engine.
The air conditioner compressor will need to be removed as will the water pump belt tensioner. Some long ring spanners will be helpful here and remember, there is no tensioner for the air con compressor, so take it slowly here.
The thermostat is located in the top left corner of the block (if you are sitting in front of the vehicle looking at the engine) and with the radiator out of the way, it is a simple task to replace the thermostat now.
The power steering bottle will have to be released but don't worry about disconnecting the hoses to and from the power steering bottle until you are sure you need to. I disconnected mine at the time, so it's not really a big issue either way. Just take note of how the hoses 'snap' into position and it's impossible to mix them up.
As you remove parts from under the headlight it will become obvious which parts need to be removed for easier access.
Once you're ready to loosen the engine mount, make sure you have a jack under the sump to take the weight as the bolts are removed from the mount/water pump.
The engine will now be able to be rolled forward enough to access the bolts holding the pump to the block. Don't apply excessive force here, you just need enough room to get to the pump bolts.
It is a little fiddly but patience will get the job done and save a lot of money.
There may be a few things I've missed here, but I am happy to provide any information as you go.
Errol.

 

[eiger]

errolmorris

As I was searching how to replace my Ducato 3.0 water pump, I found your post.
It’s exclusively and extremely helpful , and I am so encouraged to do it by my own.
I’m driving it in Japan and it’s almost impossible to have someone fix my Ducato.

I have some questions.
Did you remove AC condenser or just move it forward to remove the radiator??
Since you were saying that you detached AC compressor, I assume it should be removed.
Did you leave right side( if you are facing to the engine from outside) engine mount attached or both sides have to be detached??
It seems to be difficult to balance with floor jack if both sides are detached.
And I wanna know the trick of loosen the belt tensioner without a special tool.
Hope you are still active on this forum and I can get in touch with you.

 

[Gri]

Szia!
Fiat Ducato 2008 3.0 158 lóerős autó, hogyan tudom házilag cserélni a vízpumpát?
Tud valaki ebben segíteni?

 

[rayc]

Szia!
Fiat Ducato 2008 3.0 158 lóerős autó, hogyan tudom házilag cserélni a vízpumpát?
Tud valaki ebben segíteni?

Hi!
Fiat Ducato 2008 3.0 158 hp car, how can I change the water pump at home?
Can anyone help with this?

 

[mark pegasus]

It's been a long time since I visited when I was after some information on replacing the water pump on my 3 litre 08 Ducato. That was just over two years ago.
My research told me that the engine had to come out and that it would take the Fiat specialists from 4 to 5 days to complete at a cost of anywhere from $5,000 to $8,000 plus parts which they estimated at an extra $1,500 to $3,000 on top of the labour costs. It was not the sort of job that could be done in a home workshop. Even owners from overseas warned me not to attempt it at home and if I did want to go ahead, I would need to set aside at least a week and have access to parts.
Well, my son came to visit the other day and as I had already bought the pump from an overseas supplier at one tenth the Australian price, he decided that we should at least make a start.
Just as an aside, I bought the belt from a supplier in Victoria for the same price as the pump cost me from overseas. Go figure that one, but then I wasn't able to buy a belt from overseas anyway.
Since we have never worked on a Fiat van before, this was to be an experiment. All my research indicated a huge job ahead.
As my son suggested, it almost seems like there is a conspiracy thing happening with these poorly designed vehicles in that no one wants to disclose any information about mechanical repairs to these things and as we are both mechanics, we have the advantage of some pretty fancy and specialised tools between us. None of which we needed. The job took us about 8 hours from start to finish and neither of us had any idea what we were going to encounter.
Add to that, I am in a very remote location with the nearest spare parts supplier 6 hours drive by road from me. We had several coffee breaks while we contemplated each move and we probably could do the job again in around 5-6 hours.
If anyone would like any information, please let me know and I would be happy to share my experience.

hi my 3 litre manuel ducato long wheel base ducato , the water pump pully is a bit wobbly , I have been told it needs replacing , I have b been told the engine can be rocked back to allow room to remove the old water pump? is this how you did it , can you send some more information please how to remove the old water pump. please reply the method you used , I cannot find any local mechanic , except for a truck specialist, who claims it will take 3 days to do

 

[Arcprof]

I found this thread very useful when replacing the water pump on my 3.0 l Ducato recently. I can say it is a difficult project but can be done by a DIY handyman with basic tools and a few extras that make it much easier to do. First off here's a photo of the engine showing the engine mount (the bright silver stirrup bracket).

The water pump sits underneath the engine mount. You can just make out the pump drive pulley underneath the mount. It is the higher pulley on the aux belt route.
So the first part of the job is getting access to the engine mount. As described in earlier posts, the windscreen washer and right hand headlight need removing and the steering pump reservoir tied out of the way.
More later...

 

[Arcprof]

Before moving on I should point out that the engine does not need to come out. The photo is just to show the layout of the different parts.

After removing the right headlight, remove the bracket that supports the header tank and power steering bottle. Remove the header tank hose to the water pump and the breather hose that runs close to it.
Now support the engine from underneath and undo the 3x18 mm bolts that bolt the mount to the water pump. Check the motor does not drop too much as these are loosened. When happy that the motor isn't going anywhere, undo the 3x18 mm bolts that bolt the mount to the chassis and remove the complete engine mount.
Now you get a good view of the water pump. There are 5 bolts to remove. See the photo below. The first two are either side of the inlet from the header. Then there are 3 15mm bolts 12 o'clock, 9 o'clock and 6 o'clock. The 6 o'clock one is the hard one. I used a 15 mm socket on a long 1/2" drive tee handle. A torch allows a slight glimpse of the bolt head between the drive pulley and the block.
Once the bolts are out, a tap with a mallet should free the old water pump. Remove the rear hose and pull the pump out from above.

Clean up the face ready for the new pump. Now is a real good time to check the belt tensioner. Mine was frozen solid. If you get a spanner on the idler bolt and turn it as if tightening the bolt, the idler should arc down towards the crankshaft pulley so you can get a new belt on. If it doesn't budge, you can remove the complete tensioner by undoing the 8mm allen head bolt.
Once the tensioner is ok then bolt on the new pump. Fitting the belt is much easier with the engine mount removed so that is the next step.
More later