Oh god, long story incoming.
The car was a 1987 Nissan Maxima, the issue was a failed water pump. I managed to get a friend with a garage to give me some space to work on the car as I wasn’t about to shell out $200 for a shop to replace a $30 part. He also let me use his tools since I had only the most basic set as a 17 year old kid. Haynes manual in hand I was ready.
How hard could this be?
Well turns out when you’re 17, have almost zero patience and nothing more than a few oil changes and brake pad replacements in your DIY repertoire, pretty effin hard.
The first issue came when I tried to cheat, and not remove the timing belt covers. The lack of space between the front of the engine and the strut tower was super annoying and this seemed like a tedious process I could skip. I got about 3 of the 5 bolts out of the water pump before gave up on being able to remove it this way. So I went back and started removing the covers, oh but what’s this? You can’t remove the lower cover without removing the crank pulley. Crap. Well maybe I can cheat there too, I’ll just bend this cover a little, and bend that… crap, why won’t you come out already you giant piece of junk! The lower cover was a mangled mess from trying to remove it without removing the crank pulley. I guess I should figure out how to remove that crank pulley.
Okay how the hell do I do that? The Haynes manual didn’t really give me a good explanation, just said “remove pulley”. Thanks a lot. My first attempt was to use a ratchet and a hammer, since no air tools were to be found. The ratchet was barely longer than the crank pulley, and I wailed on it, broke the ratchet, and no sign of movement from the bolt. Okay, plan B it is. Let’s apply some leverage to this, I found a cheater bar and a long piece of pipe in the far dark corner of the shop and with those I thought I was making headway, things were turning! But when I looked, it was turning the engine over instead of removing the bolt. Well crap. How do I keep the engine from turning? Nothing in the Haynes manual on that. Let’s see.. when the crank moves.. hmm, oh! The timing belt! I’ll just lock the timing gear into place and the belt will keep the crank from turning. (This was not one of my more brilliant moves)
With the timing belt locked into place I applied all the force I could to the pipe, the pipe gave a little, then “shhhhlip” it moved quite a bit, but again, the bolt stayed in place while the crank turned…. and the cams didn’t. I didn’t think anything of this though at the time. I had the anger of a thousand suns burning in me over this stupid bolt that wouldn’t move. It was late. So I called my brother, he picked me up and I went home. Angry, hot, and caked with 12 years of engine grease and grime. This was the end of day one.
After a troubled nights rest, tossing and turning thinking about the car, I awoke to try this again. I asked my dad before heading out if he knew how to keep the engine from rotating. He wasn’t very mechanically inclined, but remembered a buddy of his in highschool taking the starter off and wedging a screw driver into the flexplate to keep things in place.
Armed with this newfound knowledge I was confident I could get this done today. And things seemed to be going better. I removed the starter with little difficulty, save for dropping years’ worth of road grime into my face when I pulled it free. After finally getting all the crud out of my eyes, I found a nice hole to slide the biggest flathead screw driver I could find through. There that should hold. I went back to the pipe, still attached to the bolt, where I left it in defeat the night before. I pushed down on the pipe with all my might, it bowed, then finally it moved, and that was all I needed, I was able to readjust the pipe and get the bolt to move more. Holy crap, I was on cloud nine at this point. This bolt was done for. I put a ratchet on it and pulled it all the way out. Time to get this pulley out of the way.
Grabbing hold of the pulley on both sides I pulled it straight towards me. Nothing. I pulled again, this time bracing my legs on the inner fender structure. Nothing. I tapped on it with a hammer, sprayed it with some WD40 and waited. My third attempt was met with the same results. My celebratory mood quickly shifted to anger. I hated this car. What was meant to be a simple 2 hour procedure was anything but that. So I did the only thing my 17 year old brain knew to do. I picked up a hammer, and laid into the pulley with all my strength to try and free it up. It only took what seemed like an eternity of pounding, but I felt it wobble and then break free entirely. But this process hadn’t been kind to the pulley, 2 giant chunks of the side wall were missing in action. I didn’t care at this point, I had bested the stupid thing and as long as the belt was lined up it shouldn’t be an issue, I thought to myself.
With the pulley finally out of the way I was able to remove the now completely mangled lower timing cover. I thought I might be able to get away without putting one back on when I put it all back together. Maybe make it easier to service in the future.. Yeah that’s the ticket. With all the stuff I had done at this point I almost forgot why I started. Oh yeah, the water pump, this 30 dollar part from Autozone.
Things went a lot easier at this point, I removed the last few bolts I couldn’t get to with the cover in the way (thanks Nissan engineers). I got the new pump on and sealed to the motor with the new gasket. I filled it up with coolant and didn’t see any leaks, so I put the upper timing cover on. I installed the crank pulley, and got all the belts lined up for the accessories. The starter was the last thing to go back in. This was it, almost 20 hours later I was done. I turned the key, the lights on the dash came on, a good sign. Then I turned the key. Something wasn’t right, it turned over, but wouldn’t catch, then smoke started coming out of the open air filter. What. The. Hell. Then it clicked. I was so pissed off from all the times this car had tried to prevent me from fixing it and so eager to have it done. I had completely forgotten about the timing being thrown completely out when the crank had slipped while the timing gears where locked.
With no telling how many valves bent I called it. I was done. I was so upset at myself. How could I have been so stupid? All that time, all that energy, blood, and sweat. Wasted. I put the tire back on. Lowered the car to the ground. Had my brother come pick me up again. I called a tow truck the next day and had it towed to a shop. I purchased a used engine for $300 and had them install it. By the time it was done, I had paid way more than the $200 to replace the water pump. Hell, I had paid 1.5 times what I purchased the car for. But teenagers are dumb, and I was no exception to the rule.