Working on the girlfriend's 82 242 TI. Replaced the water pump with a GMB kit from IPD. I keep having the problem that it seems like the heater pipe seal is too thick. (The one that came in the box!) Put it on the pipe, insert into the water pump, and one portion of it will fold back out of the hole, not sealing. I tried another aftermarket seal I got from IPD that seemed like it was made of a more pliable rubber and still have the same problem. Anybody experience this? I also tried sticking this seal into the water pump, greasing the sucker up like an Alabama sheep on a Friday night, and then sliding the pipe into it and generally the seal folds and pushes into the outlet pipe that runs to the radiator (I can feel with my finger). Irritating. Is there a perfect seal out there?

Wish I could take the stupid pipe off and play with this crap on the bench, but the damn turbo is such an obstacle.

This is the fifth water pump I've done and never had this much hassle. Grrrr. Thoughts? I'm getting to the point that I'd really just like to crimp part of the pipe orifice so that it's conical going into the water pump, but that's cheating and a bad idea down the road.

I always clean the pipe and remove everything down to the bare metal right to the shoulder. I apply a little silicone caulk and put the seal in place. I add a little more silicone caulk to the seal and install the pump. While wet the silicone acts as a lube and when it sets it acts as a seal. Best of both worlds.

Randy

Use some emery paper on the water pipe end, and then use some silicone grease on it. Put some silicone grease on the seal, and install it at the very end of the pipe. Make sure the pump recess is clean, and maybe a bit more grease there too. Slide it together, and the seal will move down the pipe as the pump recess pushes it. Works for me nearly every time.
Volvo supplies a seal that has a chamfer on the OD to ease this part of the installation, and it works, but the aftermarket guys still supply the square cut seal.

Yeah, I already cleaned the sucker down to bare metal. The female portion of the pump was obviously super clean since it was new. Somehow, after five attempts, it finally worked its way on correctly. I do like the idea of siliconing the sucker into place at the end of the pipe and allowing it to set before attempting the insertion.

Next time I'll make the trek to my buddy's Volvo shop and get the real red Volvo seals. This was ridiculous.

Rhys' method is best IMO. Get the seal started on the end of the pipe, but leave some projecting (ie unexpanded by the pipe) to start in the housing. Then each will slip into position when you push the pipe in further.