Replacing the "Water Pump O-ring"

This document will explain how to replace the water pump O-ring on Ford Falcon I6 Vehicles EA-BA inclusive.
Ford changed the design of both the heater pipe and the water pump in June 2004 so vehicles built after this date are not covered in this document. Vehicles with the updated water pump can be identified by the letters "AA" cast in the back of the pump near where the bottom radiator hose joins on. BA Falcons with the old water pump and pipe "BA" is cast into the same place.

Parts Required:
1x AU-8K540-A (O-ring)
1x BA18N318S (Spacer)

Tools Required:
10mm Socket and suitable ratchet
13mm Socket and suitable ratchet
19mm Combination Spanner (for bell housing bolt securing rear of heater pump, Except BA vehicles)
Hammer and suitable punch (for tapping the spacer into the pipe)

Replacing the O-ring, and fitting the spacer.

1. Confirm that the O-ring at the rear of the water pump (where the heater pipe joins into it) is leaking
2. Remove the cooling system cap and refit it (this lets any pressure out)
3. Remove the exhaust heat shield
4. Undo the bolts holding the heater pipe to the engine block. (rear - near/on the bell housing.)
5. Carefully pull the pipe rearward out of the water pump.
6. Inspect the recess in the back of the water pump and clean any corrosion or grime if required.
7. Replace ‘O’ ring (Be sure to use a small amount of Rubber Grease to lubricate the new O-ring)
8. Tap the spacer into the front of the heater pipe until square and flush with the end of the pipe.
(This may require removal of the engine cooling fans to get enough movement with a hammer and punch.
Sometimes the spacers go in without any need for tapping, other times its a real pain.)
9. Carefully refit the heater pipe into the water pump.
10. Fit and tighten both front and rear heater pipe bolts. (It MAY be necessary to make the holes on the
pipe slightly larger using a die grinder etc, however of the 30+ cars I've replaced this O-ring on, only one
has required this. If you feel this is required make 100% sure the spacer is fitted into the pipe correctly.)
11. Refit any other items removed to gain access.
12. Refit the exhaust manifold heat shield.
13. Refill the cooling system, and pressure test the system if you have a pressure tester available.
If you do not have a pressure tester. Run the engine until at operating temperature, confirm the vehicle is
still full of coolant and observe for any leaks. If you use this method keep a close eye on coolant level for the next
few days.