Sailing Zephyr IV · video

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Dave replaces a leaking raw water pump on the Volvo Penta 2003 marine diesel engine aboard Zephyr IV.Watch After discovering water dripping from the pump’s weep hole, he opts to install a complete new pump assembly rather than rebuilding the 30-year-old unit, citing potential wear in the pump body and past impeller failure.1:18 Accessing the pump requires removing the front cover plate and cutting off the outlet hose, which shows significant wear from vibrating against the alternator housing.1:59 Dave extracts the pump, transfers the nylon drive cog to the new unit using pointed-nose pliers to remove the circlip, and reinstalls the assembly in the confined engine space.3:03 He replaces the damaged outlet hose with high-specification, fireproof automotive heater hose sourced from a local supplier after failing to find a standard match at a chandlery.4:15 Final testing confirms proper cooling water flow through the exhaust and telltale with no leaks.5:12 Replacing the pump is straightforward, though engine bay access remains the primary challenge.5:31

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