Help..... Grande problem.

[jocko]

Gents,
Recently swapped a T5 into my truck - one of the problems I ran into was I thought that in the process of jacking my engine around (bell hsg mounts removed, front mounts still attached) and having the fan kinda impinge on the fan shroud accidentally that I busted the water pump shaft seal - because I found that a butt load of coolant had leaked out one day. But it was a little while after I had re-installed the engine in the proper place. Strange. Not normal for an engine to suddenly dump most of its coolant - when not running...

So, replaced the water pump. Blue permatex, the wholel deal. Water pissing out near the lower passenger side bolt at a pretty high rate (i.e. just when re-filling the system - not even pressurized or engine running, etc).

So, yanked that bolt thinking I forgot to seal the threads (which I had) and put a good wrapping of teflon tape around the bolt and re-torqued it.

But it's still leaking. Pretty bad. Gasket appears to be in place, hasn't bulged out or slipped out of place, etc, so no problem there (I think). So, I'm gonna have to tear the whole #$%$%^ thing apart again to figure out the problem.

I RTV sealed the gasket front and back and used white teflon tape on the bolts, yet still leaking out the side - the arrow in the pic shows the exact spot it was pissing out. My MAIN worry is, heaven forbid, that I somehow cracked the block at this mating junction between pump and block - because the pump is brand new. It COULD be that I have two separate problems - originally bad water pump. THEN, a leaky gasket, but it sure is pissin out - it's not just dripping. Wasn't obvious until I saw a massive puddle under the truck that I even noticed the leak.

This is the side of the pump that uses the whole gasket, i.e. not the side that has the extra part of the gasket hanging out becuase they just give you two identical gaskets.

What could I be missing here?

Anyone ever hear of such a silly thing as a cracked block in this location?
Seems it's GOTTA be a gasket leak or bolt leak.

What do you use to sel your bolts? I used white teflon tape. Is blue RTV or white liquid sealant better?

How much blue rtv do you slap on both sides of the gasket? I smeared it on by hand - but didn't let it get too thick. In the pic, I notice there is no RTV squeezed out where the leak is, so gonna look closely at the gasket in that location.

There's that "extra" hole in the gasket on that side - wondering if that could be an issue....

Gonna pull the whole thing and probably replace the gaskets while I investigate - I can't SEE a block crack, but pretty worried. Will have made this T5 a waste of money. Anyway, more to come - but wanted to get your thoughts before I get too pissed off at this little blue truck. Aw, I still love er, but she better start moving SOON, the ol piece of crap.

Thanks,
Jocko