Bruno and Mike - you're welcome. The board has been very helpful for me, so it's a pleasure to actually contribute for a change.

Bruno:

IMO, air injection may exist as an emissions mandate, but it serves a purpose. Bypassing air injection can have long term effects (performance and longevity) of other components, especially the catalytic converter(s).

If you go ahead with your rebuild, post your questions and we will work through them.

Mike:

I was amazed at the prices these pumps command. It made the decision to attempt my own repair pretty easy. As I already wrote, others trod this path before me, and it was obvious that sourcing the pulley bearing was the biggest problem. That problem should go away for anyone else wishing to do their own rebuild. I should have posted that my total investment (both bearings and shipping) was just under $50 - and I paid a premium for the pulley bearing. I wanted to give my business to a bearing supplier who went the extra mile talking with me by identifying the correct Timken bearing for the carrier cover.