Water Pump Replacement 4.3 L Engine
Tools Required
J 41240 Fan Clutch
Remover and Installer
Removal Procedure
- Separate the MAF/IAT sensor
assembly and the air inlet tube by loosening the hose clamp.
- Disconnect the PCV hose from the air cleaner outlet duct.
- Remove the air inlet tube
and resonator retaining wing nut.
- Remove the air inlet tube
and resonator from the throttle body by pivoting the air inlet tube and resonator
upward until the hinge clip releases from the lip on the throttle body.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
- Remove the upper fan shroud. Refer to
Engine Coolant Fan Upper Shroud Replacement
.
- Remove the cooling fan and clutch assembly. Refer to
Fan Clutch Replacement
.
- Remove the drive belt. Refer to
Drive Belt Replacement
in Engine Mechanical-4.3L.
- Remove the radiator outlet hose from the water pump. Refer to
Radiator Outlet Hose Replacement
.
- Remove the by-pass hose.
- Remove the bolts and the
fan and water pump pulley using the J 41240
.
- Remove the water pump
bolts.
- Remove the water pump.
- Remove the water pump gaskets.
- Discard the water pump gaskets.
- Remove the old gasket
material from the water pump sealing surfaces.
- Clean all the dirt and any debris from the water pump.
- Inspect the water pump for the following:
• | Leakage or damage to the housing cover or gasket (1) |
• | Excessive scratches or gouging to the gasket sealing surfaces
(2) |
• | Leakage from the water pump vent hole (3) |
• | A stain around the vent hole is acceptable. If leakage occurred (dripping)
with the engine operating and the cooling system pressurized, then replace
the water pump. |
• | Damaged bolt hole threads (4) |
• | Excessive side-to-side movement of the water pump shaft (5) |
• | Leakage around the water inlet pipe (6) |
• | Leakage around the heater hose pipe (7) |
• | Restrictions within the internal coolant passages |
Installation Procedure
- If reusing the fasteners,
apply sealant GM P/N 12346004 or equivalent to the threads of
the water pump bolts.
- Install the water pump and the NEW water pump gaskets.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the water
pump bolts.
Tighten
Tighten the water pump bolts to 45 N·m (33 lb ft).
- Install the fan and water
pump pulley and bolts using the J 41240
.
Tighten
Tighten the fan and water pump pulley bolts to 25 N·m (18 lb ft).
Important: After final assembly, the by-pass hose clamp tangs (water pump end)
must point forward and the upper tang should be level with the outside diameter
of the by-pass hose.
- Install the by-pass hose.
- Connect the radiator outlet hose to the water pump. Refer to
Radiator Outlet Hose Replacement
.
- Install the drive belt. Refer to
Drive Belt Replacement
in Engine Mechanical -4.3 L.
- Install the cooling fan and clutch assembly. Refer to
Fan Clutch Replacement
.
- Install the upper fan shroud. Refer to
Engine Coolant Fan Upper Shroud Replacement
.
- Align the hinge clip with
the lip on the throttle body.
Install the air inlet tube and resonator to the throttle body by pivoting
the air inlet tube and resonator downward until the mounting stud is through
the hole in the air inlet tube.
- Install the resonator
retaining wing nut.
Tighten
Tighten the resonator wing nut to 3 N·m (27 lb in).
- Connect the PCV hose to the air cleaner outlet duct.
- Connect the MAF/IAT sensor
assembly harness connector.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Inspect the cooling system for leaks.
Water Pump Replacement 4.8L, 5.3L, and 6.0L Engines
Removal Procedure
- Drain the cooling system.
Refer to
Cooling System Draining and Filling
.
- Loosen the air cleaner outlet duct clamps at the following locations:
• | Mass airflow/intake air temperature (MAF/IAT) sensor |
- Remove the radiator inlet hose clip from the outlet duct.
- Remove the air cleaner outlet duct.
- If necessary, remove the
engine sight shield. Refer to
Upper Intake Manifold Sight Shield Replacement
in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
- Remove the radiator vent inlet hose from the radiator hose clips.
- Reposition the inlet hose
clamp at the water pump.
- Remove the inlet hose from the water pump.
- Remove the fan blade. Refer to
Fan Replacement
.
- Remove the accessory drive belt. Refer to
Drive Belt Replacement - Accessory
in Engine Mechanical - 4.8L,
5.3L, and 6.0L.
- Reposition the outlet
hose clamp at the water pump.
- Remove the outlet hose from the water pump.
- Reposition the surge tank
outlet hose clamp at the water pump.
- Remove the surge tank outlet hose from the water pump.
- Reposition the heater
inlet hose clamp at the water pump.
- Remove the heater inlet hose from the water pump.
- Remove the water pump
bolts.
- Remove the water pump and gaskets.
- Discard the water pump gaskets.
Installation Procedure
Important: All gaskets surfaces are to be free of oil or other foreign material
during assembly.
- Install the water pump
and NEW gaskets.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the water pump bolts.
Tighten
- Tighten the water pump bolts a first pass to 15 N·m
(11 lb ft).
- Tighten the water pump bolts a final pass to 30 N·m
(22 lb ft).
- Install the heater inlet
hose to the water pump.
- Position the heater inlet hose clamp at the water pump.
- Install the surge tank
outlet hose to the water pump.
- Position the surge tank outlet hose clamp at the water pump.
- Install the outlet hose
to the water pump.
- Position the outlet hose clamp at the water pump.
- Install the accessory drive belt. Refer to
Drive Belt Replacement - Accessory
in Engine Mechanical - 4.8L,
5.3L, and 6.0L.
- Install the fan blade. Refer to
Fan Replacement
.
- Install the inlet hose
to the water pump.
- Position the inlet hose clamp at the water pump.
- Install the engine vent
inlet hose to the radiator hose clips.
- If necessary, install the engine sight shield. Refer to
Upper Intake Manifold Sight Shield Replacement
in Engine Mechanical
- 4.8L, 5.3L, and 6.0 L.
Important: Align the arrow at the throttle body end of the duct with the throttle
body attaching stud.
- Install the air cleaner outlet duct.
- Install the radiator inlet hose clip to the outlet duct.
- Tighten the air cleaner outlet duct clamps at the following locations:
Tighten
Tighten the air cleaner outlet duct clamp screws to 7 N·m
(62 lb in).
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
Water Pump Replacement 8.1L Engine
Removal Procedure
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
- Remove the drive belt. Refer to
Drive Belt Replacement - Accessory
in Engine Mechanical - 8.1 L.
- Remove the fan clutch. Refer to
Fan Clutch Replacement
.
- Reposition the outlet hose clamp at the water pump.
- Remove the outlet hose from the water pump.
- Reposition the bypass hose clamps at the water pump and water crossover.
- Remove the bypass hose.
- Remove the water pump
bolts.
- Remove the water pump.
- Remove and discard the water pump gaskets.
Installation Procedure
- Place NEW water pump gaskets
into place.
- Install the water pump.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the water pump bolts.
Tighten
Tighten the water pump bolts to 50 N·m (37 lb ft).
- Install the bypass hose.
- Position the bypass hose clamps at the water pump and water crossover.
- Install the outlet hose to the water
pump.
- Position the outlet hose clamp at the water pump.
- Install the fan clutch. Refer to
Fan Clutch Replacement
.
- Install the drive belt. Refer to
Drive Belt Replacement - Accessory
in Engine Mechanical - 8.1 L.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
Water Pump Replacement 6.6 L Engine
Removal Procedure
- Remove the left front fender wheelhouse inner panel (1).
- Drain the engine coolant and the engine block. Refer to
Cooling System Draining and Filling
.
- Remove the thermostat housing crossover. Refer to
Thermostat Housing Crossover Replacement
.
- Remove the fan clutch. Refer to
Fan Clutch Replacement
.
- Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement
in Engine Mechanical - 6.6L.
- Remove the water pump outlet pipe to water pump nuts.
- Remove the engine wiring harness retainer from the inner stud.
- Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths.
- Remove the water pump assembly.
- Remove the water pump outlet pipe gasket.
Inspection and Repair Procedure
- Remove the O-ring from the water pump.
- Remove the water pump to water pump housing bolts.
- Remove the water pump from the water pump housing.
- Remove the O-ring from the water pump housing.
- Clean the water pump assembly.
- Clean the water pump mating surfaces.
- Inspect the water pump gear for damage.
- Inspect the water pump mating surfaces for damage.
- Inspect the water pump shaft for looseness.
- Inspect the water pump assembly for damage.
- Replace the water pump if any damage is found.
- Install a new O-ring to the water pump housing.
- Lubricate the O-ring with engine coolant.
- Install the water pump to the water pump housing.
Notice: Refer to Fastener Notice in the Preface section.
- Install the water pump to water pump housing bolts.
Tighten
Tighten the water pump to water pump housing bolts to 21 N·m (15 lb ft).
- Install a new O-ring to the water pump.
Installation Procedure
- Lubricate the water pump O-ring with engine oil.
- Install the water pump.
- Install the water pump bolts. Ensure the correct length bolt is used in the proper location.
Tighten
Tighten the water pump bolts to 21 N·m (15 lb ft).
- Install the water pump to water pump outlet pipe gasket.
- Install the engine wiring harness retainer on the water pump outlet pipe inner stud.
- Install the water pump to water pump outlet pipe nuts.
Tighten
Tighten the water pump to water pump outlet pipe nuts to 21 N·m (15 lb ft).
- Install the thermostat housing crossover. Refer to
Thermostat Housing Crossover Replacement
.
- Install the crankshaft balancer. Refer to
Crankshaft Balancer Replacement
in Engine Mechanical - 6.6L.
- Install the fan clutch. Refer to
Fan Clutch Replacement
.
- Fill the engine with coolant. Refer to
Cooling System Draining and Filling
.
- Install the left front fender wheelhouse inner panel (1).