Originally Posted by MMZ_TimeLord
Steve,
The Johnson pump swap was something like this... didn't have to jack up the car. Didn't have to take the wheel off (kinda cramped, looking back I probably would jack the car up enough to remove the passenger side wheel for easy access to the inner fender cover.)
Remove the front inner fender cover.
Disconnect the wiring.
Unclamp old pump, have a wide catch basin ready (3 to 4 inch deep storage tub works fine) and just swap out.
Replace the pump. You should replace the factory clamps with standard hose clamps as the hoses are just slightly loose on the new pump. (only did one on mine with no leaks ... yet)
Now, what I did was tin the wire ends that come on the johnson pump and insert them into the OEM plug from the wire harness. Then using gaffer's tape (you can use heat shrink tubing too) to seal it up.
Start engine and check for leaks. Let it run for about 10 minutes. Rev once or twice to force air out of the system.
Filter and add the recovered fluid from catch basin.(storage tub in my case)
Replace inner fender cover.
NOTE: I think you have to take off the front underside cover (4 bolts) to get the inner fender cover off.
Hope that helps.
Thanks for the info. I'm thinking I had read in a post a while back that someone was selling the Johnson pumps that had the correct size fittings as the OEM pump. Is this the one you got or did you have to reuse your OEM one's? I've changed my mind about getting the smaller battery to make room for seperating the cooling systems. I've got a small universial cylinder shaped billit reservior ordered and I'm going to use it for the radiator overflow and use the OEM overflow tank for just the S/C system. I'm also looking into adding another small heat exchanger/aftercooler, I'm looking for a fan cooled one thin enough to fit. Is the system's OEM hose's 1/2" ID, I've got the car partically tore down, but don't want to open up the system till I have all the parts I'm gonig to need.