Amazon: Amazon radiator return pipe problems

[superspod]

Hi all,
Just wondering if anyone had some useful advice for this as you usually do! Managed to localise the source of the persistent puddle under the car to the junction between the hose from the bottom of the radiator and the pipe heading up to the water pump. Essentially the metal had corroded to the point that that tube is functionally never going to be able to make a suitable deal.
After disassembling (and ensuring no remnants of anything remain in the pump) I tried inserting a new pipe from Brookhouse with a new o ring to no avail, trying o ring lube etc. On inspection the dimensions of the new pipe Vs old pipe do appear slightly different with the new one being longer, but even with the new o ring I'm struggling to get the old pipe to align so I can fit the bolt into the engine block even with significant force.
Short of modifying the pipe, has anyone got any suggestions as to what might be going on? Searching the forums and Haynes manual hasn't provided much help!

[Volvo_133]

You may have tried this, can you slot both the old and new pipes into the water pump (minus the o ring) and fit the bolt through the timing cover.?

[superspod]

Originally Posted by Volvo_133

You may have tried this, can you slot both the old and new pipes into the water pump (minus the o ring) and fit the bolt through the timing cover.?

Thanks for your reply! I have, they both only just line up, but I can't see how it would fit with the o ring there?

[Volvo_133]

Try fitting the new pipe minus the o ring. Pencil mark the pipe at the pump base.
Remove pipe, fit o ring to pencil line, attempt to fit the pipe.

[Volvo_133]

It is many years since I replaced the water pump, my above idea will be useless if the pipe has a shoulder/collar inbuilt to support the o ring.

[Volvo_133]

Thoroughly clean the W. Pump port with emery cloth or wire wool. Put a thin layer of rubber grease on pipe and o ring. Good luck.