Water Pump: Service and Repair

Water Pump Removal

1. Drain cooling system.

2. On EFI engines, remove fan shroud retaining screws. Remove fan/clutch assembly retaining bolts.

3. Remove fan/clutch assembly and shroud.

4. Rotate main accessory drive belt tensioner. Remove main drive belt and water pump pulley.

5. Remove power steering pump pulley and remove water pump to power steering pump brace.

NOTE:On supercharged engines, it may be necessary to remove the intercooler to gain access to power steering pump pulley. Refer to Intercooler/Charge Air Cooler (CAC) Service and Repair.

6. On EFI engines, disconnect coolant bypass hoses at water pump. On supercharged engines, disconnect oil cooler tube and bypass hose.

7. Disconnect heater hose at water pump (EFI engines) and disconnect lower radiator hose.

8. Remove upper crankshaft sensor cover (supercharged engines).

9. Remove water pump retaining bolts and pump. Discard old gasket.


CAUTION:If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces.

Installation

NOTE:Lightly oil all bolt and stud threads before installation except those specifying special sealant.

1. Clean gasket surfaces on water pump and front cover.

2. Position a new gasket on water pump sealing surface.


NOTE:Gasket and Trim Adhesive D7AZ-1 9B508-AA (ES R-M 11 P17-A and ESE-M2G52-A) or equivalent is recommended to hold the gasket in position.


3. Position water pump on the front cover. Install retaining bolts.

NOTE:The threads of the No.1 water pump retaining bolt must be coated with Pipe Sealant with Teflon© D8AZ-19554-A (ESG-M4G194-A) or equivalent before installing.

Tighten retaining bolts to 20-30 N-m (15-22 lb-ft).

4. Install upper crankshaft sensor cover (supercharged engines).

5. Connect cooling bypass hose, heater hose, oil cooler hose and radiator lower hose to water pump. Tighten clamps securely.

6. Install water pump to power steering pump brace and install pump pulley.

NOTE:If removed, install intercooler assembly. Refer to Intercooler/Charge Air Cooler (CAC) Service and Repair.

7. Position main accessory drive belt over the pulleys.

8. Install water pump pulley, fan/clutch assembly and fan shroud. Cross-tighten fan/clutch assembly retaining bolts to 16-24 N-m (12-18 lb-ft).

9. Rotate tensioner and install drive belt.


10. Fill cooling system with specified coolant.

CAUTION:This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant formula to avoid cooling system damage.

11. Start engine and check for coolant leaks.