Water Pump: Service and Repair

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable from the battery.





Caution: Refer to Battery Disconnect Caution in Service Precautions.

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





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





5. Remove the air intake duct from the turbocharger.





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





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





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





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 (Left) or Accessory Mounting Brackets Replacement (Right).





15. Remove the left accessory bracket from the engine block. Refer to Engine Mount Replacement (Left) or Engine Mount Replacement (Right).





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.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the mounting bolt behind the water pump plate.
^ Tighten the bolt to 28 Nm (21 ft. lbs.).





4. Install the water pump and backing plate to the engine.
^ Tighten the water pump plate retaining bolts to 23 Nm (17 ft. lbs.).





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 (Left) or Engine Mount Replacement (Right).





7. Install the right accessory bracket to the engine block. Refer to Accessory Mounting Brackets Replacement (Left) or Accessory Mounting Brackets Replacement (Right).





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 the water pump pulley mounting bolts to 25 Nm (18 ft. lbs.).





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 Cooling System.





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





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





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 Draining and Filling Cooling System in Cooling System.
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.
21. Inspect the system for coolant leaks. Refer to Cooling System Leak Testing (Radiator Leak Test).