Replacement procedures are below. Basic mechanics tools all that is needed (wrenches, sockets, screwdrivers etc.)
Disconnect the negative battery cable.
Drain the engine cooling system.
For 5.3L engines, loosen the air cleaner outlet duct clamps at the throttle body and Mass Airflow/Intake Air Temperature (MAP/IAT) sensor. Remove the bolt and air cleaner outlet duct.
Relieve the belt tension and remove the accessory drive belts or the serpentine drive belt, as applicable.
For the hoses on some engines, removal may be easier if the hose is left attached until the pump is free from the block. Once the pump is removed from the engine, the pump may be pulled (giving a better grip and greater leverage) from the tight hose connection.
Note the positions of all retainers as some engines will utilize different length fasteners in different locations and/or bolts and studs in different locations.
Remove or disconnect the following:
Upper fan shroud
Fan or fan and clutch assembly, as applicable
Water pump pulley; use a suitable tool to hold the pulley while removing the bolts
Coolant hose(s) from the water pump
Water pump retainers
Water pump from the engine
Clean the gasket mounting surfaces.
The water pumps on some of the engines covered may have been installed using sealer only, no gasket, at the factory. If a gasket is supplied with the replacement part, it should be used. Otherwise, a 1 / 8 in. (3mm) bead of RTV sealer should be used around the sealing surface of the pump.
Apply sealant to the water pump retainer threads.
Install or connect the following:
Water pump using a new gasket. Tighten the water pump retainers to 89 inch lbs. (10 Nm) for 4.2L engines, or to 30 ft. Lbs. (41 Nm) for 4.3L engines. For 5.3L engines, tighten the bolts to 11 ft. Lbs. (15 Nm), then to 22 ft. Lbs. (30 Nm).
Water pump pulley. Tighten the pulley bolts to 18 ft. Lbs. (25 Nm).
Fan or fan and clutch assembly
Serpentine drive belt (if equipped) by positioning the belt over the pulleys and carefully allow the tensioner back into contact with the belt.
V-belts (if equipped) and adjust the tension
Upper fan shroud
Negative battery cable
Refill the engine cooling system.
Run the engine and check for leaks.
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Friday, March 20th, 2009 AT 5:11 PM