The car is a 1988 Mazda with a 4-cylinder 1.6L B6 engine. I noticed earlier in the year a puddle of coolant under the engine near the crankshaft pulley. Since it was time to replace the timing belt I bought a replacement water pump. I did note that the bottom right bolt holding on the original water pump came loose with not much effort. Pulled the old water pump off and saw what appears to signs of leaking at the gasket with rusting of the mating surface. Here's a picture of the mating surface:
I checked all the bolts and even made the bottom bolts tighter, still I see a drop of coolant appear at the bottom right of the pump. I figure if it can't hold coolant with the engine not on, it's not going to hold under pressure and heat. So I go out and get some Permatex gasket sealer made just for water pumps. Use it all around the engine mating surface and the attaching bolts, reusing the gasket that leaked also. Put it all back together again and the coolant seems to be holding - sort of. I'm still seeing about a tablespoon of coolant collecting at the bottom of the engine after the car has been driven and sitting for the night.
The Permatex directions cautioned to not overtighten the bolts or the sealant will squeeze out and won't do any good. I just don't know what to do. Does the engine surface that contacts the water pump need to be sanded down to bare metal? I was afraid to get too aggressive with a chisel and scratch the surface, causing more problems. Is there a tightening sequence for the bolts? More gasket? Permatex form-a-gasket? I'm very sure the water pump itself isn't leaking, it's coming from the joint of the pump and engine, I just don't know how to make a tight seal that won't leak. It almost appears by design that the bottom right bolt is too far away to pull the water pump close to the engine.....
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