Water Pump Replacement 4.3L

Removal Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Partially drain the coolant. Refer to Cooling System Draining and Filling .



2. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 4.3L.
3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
4. Remove the upper fan shroud. Refer to Radiator Replacement .
5. Remove the fan and the clutch from the engine. Refer to Fan Clutch Replacement .
6. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 4.3L.
7. Remove the coolant pump pulley retaining bolts and the pulley.



8. Disconnect the lower radiator hose from the coolant pump.
9. Disconnect the by-pass hose from the coolant pump.



10. Remove the coolant pump retaining bolts.
11. Remove the coolant pump and the gasket.
12. Clean the coolant pump mating surfaces.

Installation Procedure

1. Install the gasket and the coolant 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.

2. Install the coolant pump retaining bolts.

Tighten
Tighten the coolant pump retaining bolts on the to 41 N·m (30 lb in).

3. Connect the by-pass hose to the coolant pump.



4. Connect the lower radiator hose to the coolant pump.



5. Install the coolant pump pulley.
6. Install the fan and the clutch to the engine. Refer to Fan Clutch Replacement .
7. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 4.3L.
8. Install the upper fan shroud. Refer to Radiator Replacement .
9. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
10. Install the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 4.3L.
11. Refill the coolant. Refer to Cooling System Draining and Filling .
12. Bleed the air from the cooling system.
13. Inspect the system for coolant leaks.

Water Pump Replacement 5.0L and 5.7L

Removal Procedure

1. Partially drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner and the duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 5.0L and 5.7L.
3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
4. Remove the upper fan shroud. Refer to Radiator Replacement .
5. Remove the fan and the clutch from the engine. Refer to Fan Clutch Replacement .
6. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 5.0L and 5.7L.
7. Remove the coolant pump pulley retaining bolts and the pulley.



8. Disconnect the lower radiator hose from the coolant pump.
9. Disconnect the by-pass hose from the coolant pump.



10. Remove the coolant pump retaining bolts.
11. Remove the coolant pump and the gasket.
12. Clean the coolant pump mating surfaces.

Installation Procedure

1. Install the gasket and the coolant 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.

2. Install the coolant pump retaining bolts.

Tighten
Tighten the coolant pump retaining bolts on the to 45 N·m (33 lb ft).

3. Connect the by-pass hose to the coolant pump.



4. Connect the lower radiator hose to the coolant pump.



5. Install the coolant pump pulley.
6. Install the fan and the clutch to the engine. Refer to Fan Clutch Replacement in Engine Cooling.
7. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 5.0L and 5.7L.
8. Install the upper fan shroud. Refer to Radiator Replacement .
9. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
10. Install the air cleaner and the duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 5.0L and 5.7L.
11. Refill the coolant. Refer to Cooling System Draining and Filling .
12. Bleed the air from the cooling system.
13. Inspect the system for coolant leaks.

Water Pump Replacement 7.4L

Removal Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Partially drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 7.4L.
3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
4. Remove the upper fan shroud. Refer to Radiator Replacement .
5. Remove the fan and the clutch from the engine. Refer to Fan Clutch Replacement in Engine Cooling.
6. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 7.4L.
7. Remove the coolant pump pulley retaining bolts and the pulley.



8. Disconnect the lower radiator hose from the coolant pump.
9. Disconnect the by-pass hose from the coolant pump.



10. Remove the coolant pump retaining bolts.
11. Remove the coolant pump and the gasket.
12. Clean the coolant pump mating surfaces.

Installation Procedure

1. For the 7.4L, install the gasket and the coolant 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.

2. Install the coolant pump retaining bolts.

Tighten
Tighten the coolant pump retaining bolts on the to 41 N·m (30 lb in).

3. Connect the by-pass hose to the coolant pump.



4. Connect the lower radiator hose to the coolant pump.



5. Install the coolant pump pulley.
6. Install the fan and the clutch to the engine. Refer to Fan Clutch Replacement .
7. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 7.4L.
8. Install the upper fan shroud. Refer to Radiator Replacement .
9. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
10. Install the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 7.4L.
11. Refill the coolant. Refer to Cooling System Draining and Filling .
12. Bleed the air from the cooling system.
13. Inspect the system for coolant leaks.

Water Pump Replacement 6.5L Diesel

Removal Procedure

1. Partially drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner and the duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 6.5L.
3. Remove the surge tank. Refer to Surge Tank (Diesel) Replacement .
4. Remove the upper fan shroud. Refer to Radiator Replacement .
5. Remove the fan and the clutch from the engine. Refer to Fan Clutch Replacement .
6. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 6.5L.
7. Remove the coolant pump pulley retaining bolts and the pulley.



8. Disconnect the lower radiator hose from the coolant pump.
9. Disconnect the by-pass hose from the coolant pump.
10. Remove the vacuum pump from the engine. Refer to Engine Mechanical.
11. Remove the generator bracket from the engine. Refer to Generator Replacement in Engine Electrical.



12. Remove the coolant pump retaining bolts.
13. Remove the coolant pump and the gasket.
14. Remove the coolant pump plate from the engine.



15. Remove the bolt from the back of the coolant pump backing plate.
16. Clean the coolant pump mating surfaces.

Installation Procedure

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.

1. Install the coolant pump to the backing plate.

Tighten
Tighten the retaining bolt behind the coolant pump plate to 28 N·m (21 lb ft).




2. Install the coolant pump and backing plate to the engine.

Tighten
Tighten the coolant pump plate retaining bolts to 23 N·m (17 lb ft).

3. Connect the by-pass hose to the coolant pump.



4. Connect the lower radiator hose to the coolant pump.
5. Install the generator bracket to the engine. Refer to Generator Replacement in Engine Electrical.
6. Install the vacuum pump to the engine.



7. Install the coolant pump pulley.
8. Install the fan and the clutch to the engine. Refer to Fan Clutch Replacement in Engine Cooling.
9. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical -- 6.5L.
10. Install upper radiator shroud. Refer to Radiator Replacement .
11. Install the surge tank. Refer to Surge Tank (Diesel) Replacement .
12. Install the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 6.5L.
13. Refill the coolant. Refer to Cooling System Draining and Filling .
14. Inspect the system for coolant leaks.