Water Pump Replacement 4.3L

Removal Procedure

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable from the battery terminal.



2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
3. Drain the engine cooling system. Refer to Cooling System Draining and Filling .



4. Remove the air intake duct from the throttle body.



5. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .



6. Remove the upper fan shroud. Refer to Fan Shroud Replacement .



7. Remove the fan clutch assembly from the vehicle. Refer to Fan Clutch Replacement .



8. Remove the drive belt from the vehicle (A/C shown). Refer to Drive Belt Replacement in Engine Mechanical.



9. Remove the water pump pulley mounting bolts.
10. Remove the water pump pulley from the water pump.



11. Disconnect the lower radiator hose from the water pump.



12. Disconnect the by-pass hose from the water pump.



13. Remove the heater outlet hose from the water pump.



14. Remove the water pump mounting bolts.
15. Remove the water pump and the gasket.
16. Clean and inspect the sealing surfaces of the engine block.
17. Clean the water pump mounting bolts, and check the threads for damage.

Installation Procedure

1. Install the gasket and the water coolant pump.
2. Apply GM P/N 12346004 or equivalent thread sealant on the water pump mounting bolts.



3. Install the water pump mounting bolts.

Tighten
Tighten the bolts to 42 N·m (31 lb ft).




4. Install the heater outlet hose to the water pump.



5. Install the by-pass hose to the water pump.



6. Connect the lower radiator hose to the water pump.



7. Install the water pump pulley to the water pump.
8. Install the water pump pulley mounting bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




9. Install the drive belt in the vehicle. Refer to Drive Belt Replacement in Engine Mechanical.



10. Install the fan clutch in the vehicle. Refer to Fan Clutch Replacement .



11. Install the upper fan shroud. Refer to Fan Shroud Replacement .



12. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .



13. Install the air intake duct to the throttle body.
14. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls.
15. Connect the battery negative cable to the battery terminal.

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.

16. Refill the engine coolant system. Refer to Cooling System Draining and Filling .
17. Bleed the air from the cooling system.
18. Inspect the system for coolant leaks. Refer to Cooling System Leak Testing .

Water Pump Replacement 5.0/5.7L

Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable from the battery terminal.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
3. Drain the engine cooling system. Refer to Cooling System Draining and Filling .



4. Remove the air intake duct from the throttle body.



5. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .



6. Remove the upper fan shroud. Refer to Fan Shroud Replacement .



7. Remove the fan clutch assembly from the vehicle. Refer to Fan Clutch Replacement .



8. Remove the drive belt from the vehicle (A/C shown). Refer to Drive Belt Replacement in Engine Mechanical.



9. Remove the water pump pulley mounting bolts.
10. Remove the water pump pulley from the water pump.



11. Disconnect the lower radiator hose from the water pump.



12. Disconnect the by-pass hose from the water pump.



13. Remove the heater outlet hose from the water pump.



14. Remove the water pump mounting bolts.
15. Remove the water pump and the gasket.
16. Clean and inspect the sealing surfaces of the engine block.
17. Clean the water pump mounting bolts, and check the threads for damage.

Installation Procedure

1. Install the gaskets and the water pump.
2. Apply GM P/N 12346004 or equivalent thread sealant on the water pump mounting bolts.



3. Install the water pump mounting bolts.

Tighten
Tighten the bolts to 45 N·m (33 lb ft).




4. Install the heater outlet hose to the water pump.



5. Install the by-pass hose to the water pump.



6. Install the lower radiator hose to the coolant pump.



7. Install the water pump pulley to the water pump.
8. Install the water pump pulley mounting bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




9. Install the drive belt in the vehicle. Refer to Drive Belt Replacement in Engine Mechanical.



10. Install the fan clutch in the vehicle. Refer to Fan Clutch Replacement .



11. Install the upper fan shroud. Refer to Fan Shroud Replacement .



12. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .



13. Install the air duct to the throttle body.
14. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls.
15. Connect the battery negative cable.
16. Refill the engine coolant system. Refer to Cooling System Draining and Filling .
17. Bleed the air from the cooling system.
18. Inspect the system for coolant leaks. Refer to Cooling System Leak Testing .

Water Pump Replacement 7.4L

Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable from the battery terminal.
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
4. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
5. Remove the upper fan shroud. Refer to Fan Shroud Replacement .



6. Remove the fan clutch from the engine. Refer to Fan Clutch Replacement .
7. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
8. Remove the water pump pulley.



9. Disconnect the lower radiator hose from the water pump.



10. Disconnect the by-pass hose from the water pump.



11. Remove the water pump retaining bolts.
12. Remove the water pump and the gasket.
13. Clean the water pump mating surfaces.

Installation Procedure

1. Install the gaskets and the water pump.

Apply GM P/N 12346004 or equivalent thread sealant on the water pump mounting bolts.

2. Install the water pump mounting bolts.

Tighten
Tighten the bolts to 42 N·m (31 lb ft).




3. Install the by-pass hose to the water pump.



4. Install the lower radiator hose to the water pump.



5. Install the water pump pulley.
6. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
7. Install the fan clutch to the engine. Refer to Fan Clutch Replacement .



8. Install the upper fan shroud. Refer to Fan Shroud Replacement .
9. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
10. Install the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
11. Connect the negative battery cable to the battery.

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.

12. Refill the coolant. Refer to Cooling System Draining and Filling .
13. Bleed the air from the cooling system.
14. Inspect the system for coolant leaks. Refer to Cooling System Leak Testing .

Water Pump Replacement 6.5L Diesel

Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable from the battery.




Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable from the auxiliary battery
3. Drain the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



4. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls.



5. Remove the air intake duct from the turbocharger.



6. Remove the surge tank from the vehicle. Refer to Surge Tank (Diesel) Replacement in Engine Cooling.



7. Remove the upper fan shroud from the radiator. Refer to Fan Shroud Replacement in Engine Cooling.



8. Remove the fan clutch from the water pump pulley. Refer to Fan Clutch Replacement in Engine Cooling.



9. Remove the drive belt from the vehicle (single generator shown). Refer to Drive Belt Replacement .



10. Remove the water pump pulley mounting bolts.
11. Remove the water pump pulley from the water pump.



12. Disconnect the lower radiator hose from the coolant pump.



13. Disconnect the by-pass hose from the water pump.



14. Remove the right accessory bracket from the engine block. Refer to Accessory Mounting Brackets Replacement in Engine Mechanical.



15. Remove the left accessory bracket from the engine block. Refer to Engine Mount Replacement in Engine Mechanical.



16. Remove the water pump mounting bolts.
17. Remove the water pump assembly from the engine front cover.



18. Remove the bolt from the back of the water pump backing plate.
19. Remove the water pump from the backing plate.
20. Remove the gasket from the water pump backing plate
21. Clean and inspect the gasket sealing surfaces of the engine front cover and water pump backing plate.
22. Clean all the water pump mounting bolts.

Installation Procedure

Important: When servicing the water pump assembly, do not apply any sealant to the water pump gasket. The water pump gasket is manufactured with the proper amount of sealant printed on it.

1. Install the water pump gasket.
2. Install the water pump to the backing plate.
3. Install the mounting bolt behind the water pump plate.

Tighten
Tighten the bolt to 28 N·m (21 lb ft).




4. Install the water pump and backing plate to the engine.

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




5. Connect the by-pass hose to the water pump.



6. Install the left accessory bracket to the engine block. Refer to Engine Mount Replacement in Engine Mechanical.



7. Install the right accessory bracket to the engine block. Refer to Accessory Mounting Brackets Replacement in Engine Mechanical.



8. Connect the lower radiator hose to the water pump.



9. Install the water pump pulley to the water pump.
10. Install the water pump pulley mounting bolts.

Tighten
Tighten the water pump pulley mounting bolts to 25 N·m (18 lb ft).




11. Install the drive belt on the vehicle (single generator shown). Refer to Drive Belt Replacement .



12. Install the fan clutch to the water pump pulley. Refer to Fan Clutch Replacement in Engine Cooling.



13. Install upper radiator shroud on the radiator. Refer to Fan Shroud Replacement in Engine Cooling.



14. Install the surge tank in the vehicle. Refer to Surge Tank (Diesel) Replacement in Engine Cooling.



15. Connect the battery negative cable to the battery.



16. Connect the battery negative cable to the auxiliary battery terminal.
17. Refill the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
18. Bleed the air from the engine cooling system by the following:

18.1.

Remove the cap from the surge tank.

18.2.

Remove the bleed screw (slotted) from the top of the thermostat housing.

18.3.

Pour anti-freeze into the surge tank, and watch for a of anti-freeze from the bleed screw.

18.4.

When a constant flow of anti-freeze is reached, closed the bleed screw at the top of the thermostat housing.

18.5.

Continue to fill the surge tank to the proper level.

18.6.

Install the cap on the surge tank.




19. Install the air intake duct to the turbocharger.



20. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls.
21. Inspect the system for coolant leaks. Refer to Cooling System Leak Testing .