Questionthe water pump went out today, what do i have to remove before getting to the water-pump?
AnswerWATER PUMP
REMOVAL
The water pump on all engines is bolted directly to the engine timing chain case/cover.
A gasket is used as a seal between the water pump and timing chain case/cover.
If water pump is replaced because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal viscous fan drive.
Disconnect negative battery cable from battery.
Drain cooling system.
Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
Remove the plastic air cleaner intake tube.
Remove two-piece fan shroud. Remove lower half first
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) Hose Clamp Tool - Typical 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 Clamp Number/Letter Location If replacement is necessary, use only an original equipment clamp with matching number or letter.
Remove upper radiator hose at radiator
The thermal viscous fan drive is attached (threaded) to the water pump hub shaft Fan Blade and Viscous Fan Drive - Typical Remove the fan/fan drive assembly from water pump by turning the mounting nut counterclockwise (as viewed from front) Threads on the 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 the water pump pulley bolts Fan Blade and Viscous Fan Drive - Typical to prevent the pulley from rotating
If water pump is being replaced, do not unbolt fan blade assembly Fan Blade and Viscous Fan Drive - Typical from the thermal viscous fan drive.
Remove fan blade/fan drive assembly from vehicle.
After removing fan blade/fan drive assembly, do not place the thermal viscous fan drive in the horizontal position. If stored horizontally, the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant.
Do not remove the water pump pulley bolts at this time.
Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic belt tensioner Automatic Belt Tensioner - Typical Relax the tension from the belt by rotating the tensioner clockwise (as viewed from front) Automatic Belt Tensioner - Typical When all belt tension has been relaxed, remove accessory drive belt
Remove the four water pump pulley-to-water pump hub bolts Fan Blade and Viscous Fan Drive - Typical and remove pulley from engine.
Remove the lower radiator hose at water pump.
Loosen heater hose coolant return tube mounting bolt Coolant Return Tube - Typical and remove tube from water pump. Discard the old tube o-ring
Remove the seven water pump mounting bolts Water Pump Bolts - Typical
Loosen the clamp at the water pump end of bypass hose Fan Blade and Viscous Fan Drive - Typical Slip the bypass hose from the water pump while removing pump from engine. Do not remove the clamp from the bypass hose.
Discard old gasket
CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
INSTALLATION
Clean gasket mating surfaces.
Using a new gasket, install water pump to engine as follows: Guide water pump fitting into bypass hose as pump is being installed. Install water pump mounting bolts Water Pump Bolts - Typical Tighten bolts in a criss-cross pattern to 40 N·m (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 Coolant Return Tube - Typical Coat the new o-ring with antifreeze before installation.
Install coolant return tube and its mounting bolt to engine Coolant Return Tube - Typical 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 N·m (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts Fan Blade and Viscous Fan Drive - Typical to prevent pulley from rotating.
Relax tension from automatic belt tensioner Automatic Belt Tensioner - Typical Install drive belt
CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to Belt Routing - All Engines for correct belt routing. The correct belt with correct length must be used.
The following belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment
Install the fan blade/viscous fan drive assembly to water pump shaft.
Install fan shroud.
Install plastic air cleaner intake tube.
Install upper radiator hose and hose clamp to radiator.
Fill cooling system.
Connect negative battery cable.
Start and warm the engine. Check for leaks.
