The water pump can be removed and installed without discharging the air conditioning system (if equipped).
Disconnect battery negative cable.
Drain cooling system. Refer to Cooling System-Draining and Filling.
Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Snap-on clamp tool (number HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.
Remove upper radiator hose clamp and hose at radiator.
Fan Blade And Viscous Fan Drive
The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive: are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous
Remove fan shroud attaching hardware (two bolts at bottom-two clips at top).
Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit.
After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant.
Do not remove water pump pulley bolts at this time.
Automatic Belt Tensioner Assembly
Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt.
Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle.
Remove lower radiator hose clamp and remove lower hose at water pump.
Remove heater hose clamp and heater hose from heater hose coolant return tube.
Coolant Return Tube
Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring.
Water Pump Bolts
Remove seven water pump mounting bolts.
Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
Clean gasket mating surfaces.
Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. Lbs.) Torque.
Position bypass hose clamp to bypass hose.
Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube.
Connect radiator lower hose to water pump.
Connect heater hose and hose clamp to coolant return tube.
Install water pump pulley. Tighten bolts to 27 Nm (20 ft. Lbs.) Torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating.
Relax tension from belt tensioner. Install accessory drive belt.
CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not' engine may overheat due to water pump rotating in wrong direction. Refer to for correct belt routing. The correct belt with correct length must be used.
Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit.
Install fan shroud.
Install fan blade/viscous fan drive assembly to water pump shaft.
Fill cooling system. Refer to Cooling System-Draining and Refilling.
Connect battery negative cable.
Saturday, November 28th, 2009 AT 5:05 AM