The water pump on all engines is bolted directly to 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

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 beinspected. Inspect for fatigue cracks, loose blades or loose rivets that could have resulted from excessive vibration. Replace fan if any ofthese conditions are found. Also check condition of the thermal viscous fan drive.

1. Disconnect negative battery cable from battery.

2. Drain cooling system.

3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.

4. Remove the plastic air cleaner intake tube.

5. Remove two-piece fan shroud. Remove lower half first.

Water Pump |Service and Repair, Procedures: Water Pump Replacement,... http://repair.alldata.com/alldata/article/display.action?componentId=74&...

1 of 6 2/26/2016 4:51 PM

Hose Clamp Tool - Typical

WARNING: Constant Tension Hose Clamps Are Used On Most Cooling System Hoses. When Removing Or Installing, UseOnly 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.

Clamp Number/Letter Location


2 of 6 2/26/2016 4:51 PM

CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an originalequipment clamp with matching number or letter.

6. Remove upper radiator hose at radiator.

Fan Blade/Viscous Fan Drive Assembly

7. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove the fan/fan drive assembly from waterpump by turning the mounting nut counterclockwise (as viewed from front). Threads on the fan drive are RIGHT RAND. A Snap-On 36MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017D5P) can be used. Place a bar or screwdriverbetween the water pump pulley bolts to prevent the pulley from rotating.

8. If water pump is being replaced, do not unbolt fan blade assembly from the thermal viscous fan drive.

9. Remove fan blade/fan drive assembly from vehicle.

10. After removing fan blade/fan drive assembly; do not place the thermal viscous fan drive in the horizontal position. If storedhorizontally, the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant.

11. Do not remove the water pump pulley bolts at this time.


3 of 6 2/26/2016 4:51 PM

Automatic Belt Tensioner - Typical

12. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic belt tensioner. Relax the tensionfrom the belt by rotating the tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drivebelt.

13. Remove the four water pump pulley-to-water pump hub bolts and remove pulley from engine.

14. Remove the lower radiator hose at water pump.


4 of 6 2/26/2016 4:51 PM

Coolant Return Tube - Typical

15. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring.


5 of 6 2/26/2016 4:51 PM

Water Pump Bolts - Typical

16. Remove the seven water pump mounting bolts.

17. Loosen the clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while removing pump fromengine. Do not remove the clamp from the bypass hose.

18. Discard old gasket.

CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.

© 2016 ALLDATA, LLC. All Rights Reserved. (Version 2.0.13792)


6 of 6 2/26/2016 4:51 PM

1. Clean gasket mating surfaces.

Water Pump Bolts - Typical

2. 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. Tighten bolts in a criss-cross pattern to 40 N.m (30 ft. lbs.) torque.

3. Position bypass hose clamp to bypass hose.

4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.

Water Pump |Service and Repair, Procedures: Water Pump Replacement, ... http://repair.alldata.com/alldata/article/display.action?componentId=74&...

1 of 4 2/26/2016 4:52 PM

Coolant Return Tube - Typical

5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.

6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This willproperly position return tube.

7. Connect radiator lower hose to water pump.

8. Connect heater hose and hose clamp to coolant return tube.


2 of 4 2/26/2016 4:52 PM


9. Install water pump pulley. Tighten bolts to 27 N.m (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts toprevent pulley from rotating.


3 of 4 2/26/2016 4:52 PM

Automatic Belt Tensioner - Typical

10. Relax tension from automatic belt tensioner. Install drive belt.

CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due towater pump rotating in wrong direction. The correct belt with correct length must be used.

11. Install the fan blade/viscous fan drive assembly to water pump shaft.

12. Install fan shroud.

13. Install plastic air cleaner intake tube.

14. Install upper radiator hose and hose clamp to radiator.

15. Fill cooling system.

16. Connect negative battery cable.

17. Start and warm the engine. Check for leaks.



4 of 4 2/26/2016 4:52 PM

1. Disconnect battery ground cable, then drain cooling system. 2. Remove upper hose clamps and hoses, then the overflow tank hose from filler neck fitting. 3. Remove fan shroud mounting bolts, then move shroud to rear on engine. 4. Remove top mounting bolts. 5. On models equipped air conditioning, remove grille, then remove condenser mounting bolts. 6. Raise and support vehicle. 7. On models equipped with automatic transmission, disconnect transmission cooler lines. 8. Remove lower radiator hoses. 9. On models equipped with automatic transmission, remove cooler lines, then cap or plug line openings. 10. While holding radiator in place, remove two lower mounting bolts, then carefully lower radiator from vehicle. 11. Reverse procedure to install.


Radiator |Service and Repair, Procedures http://repair.alldata.com/alldata/article/display.action?componentId=81&...

1 of 1 2/26/2016 4:53 PM

WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNSFROM THE COOLANT CAN OCCUR.

NOTES: ^ Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. ^ If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type. ^ Factory installed thermostat housings on all engines are installed on-a gasket with an anti-stick coating. This will aid in gasket removaland clean up.

1. Disconnect negative battery cable at battery. 2. Drain cooling system until coolant level is below thermostat. 3. If equipped with air conditioning: a. Remove engine cover from vehicle interior.

b. Remove the support bracket (generator mounting bracket-to-intake manifold) located near the rear of generator.

Thermostat |Service and Repair, Procedures: Removal http://repair.alldata.com/alldata/article/display.action?componentId=75&...

1 of 5 2/26/2016 4:54 PM

c. The generator must be partially removed. Drive belts on all engines are equipped with a spring loaded automatic belt tensioner.Remove the generator drive belt as follows: d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner. e. Rotate the tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. f. Remove belt from generator pulley. g. Remove the two generator mounting bolts. Do not remove any wiring at generator. h. Remove generator. Position generator to gain access for thermostat gasket removal.


2 of 5 2/26/2016 4:54 PM

i. Remove the three Jeep/Truck Engine Controller (JTEC) mounting bolts and remove JTEC. Do not disconnect 60-way connectorfrom JTEC. Lay JTEC aside.

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING ORINSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOLNUMBER 6094. SNAP-ON CLAMP TOOL NUMBER HPC-20, OR EQUIVALENTS MAY BE USED FOR LARGER CLAMPS. ALWAYS


3 of 5 2/26/2016 4:54 PM

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 originalequipment clamp with matching number or letter.

4. Remove upper radiator hose clamp. Remove upper radiator hose at thermostat housing. 5. Position the wiring harness (behind the thermostat housing) to gain access to thermostat housing.


4 of 5 2/26/2016 4:54 PM

6. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket.



5 of 5 2/26/2016 4:54 PM

1. Clean mating areas of intake manifold and thermostat housing.

2. Install thermostat (spring side down) into recessed machined groove on intake manifold. 3. Install gasket on intake manifold and over thermostat.

Thermostat |Service and Repair, Procedures: Installation http://repair.alldata.com/alldata/article/display.action?componentId=75&...

1 of 6 2/26/2016 4:55 PM

4. Position the thermostat housing to the intake manifold. Note the word FRONT stamped on the housing. For adequate clearance, thismust be placed towards the front of vehicle. The housing should be slightly angled forward after installation to intake manifold. 5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 Nm (200 inch lbs.) torque.

CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in intake manifold. If not, it mayresult in a cracked housing, damag4ed intake manifold threads or coolant leak.

6. Install upper radiator hose to thermostat housing. 7. Air conditioned vehicles: a. Install generator. Tighten bolts to 41 Nm (30 ft. lbs.).


2 of 6 2/26/2016 4:55 PM

b. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 Nm (40 ft. lbs.) torque.


3 of 6 2/26/2016 4:55 PM

CAUTION: When installing the-serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheatdue to the water pump rotating in the wrong direction. Refer to illustration for correct engine belt routing. The correct belt with the correctlength must be used.

c. Position the drive belt over all pulleys except the idler pulley (located between the generator and A/C compressor).


4 of 6 2/26/2016 4:55 PM

d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner. e. Rotate the socket/wrench clockwise. Place the belt over the idler pulley. Let tensioner rotate back into place. Remove wrench. Besure belt is properly seated on all pulleys.


5 of 6 2/26/2016 4:55 PM

f. Install Jeep/Truck Engine Controller (JTEC). 8. Fill cooling system. 9. Connect negative battery cable to battery.10. Start and warm engine. Check for leaks.11. Install engine cover (if A/C equipped).



6 of 6 2/26/2016 4:55 PM

Removal

NOTE:

For additional information, also refer to the Viscous Fan Drive.

Fan belt removal is not necessary to remove cooling system fan.

1. Disconnect the negative battery cable at battery

2. Remove the plastic air cleaner intake tube.

3. Remove two-piece fan shroud. Remove lower half first.

Fan Blade |Service and Repair, Procedures: Removal and Installation http://repair.alldata.com/alldata/article/display.action?componentId=78&...

1 of 3 2/26/2016 4:56 PM


4. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/fan driveassembly from water pump by turning the mounting nut counterclockwise (as viewed from front). Threads on the viscous fan drive areRIGHT HAND. A Snap-On 36 MM Fan Wrench (number 5P346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used.Place a bar or screwdriver between the water pump pulley bolts to prevent the pulley from rotating.

Do not unbolt fan blade assembly from the viscous fan drive at this time.

5. 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 fan drive could drain into its bearing assembly and contaminate the bearing lubricant.

CAUTION: Do not remove the water pump pulley-to-water pump bolts. This pulley is under spring tension.

6. Remove the four bolts securing the fan blade assembly to the viscous fan drive.

Installation

1. Install fan blade assembly to viscous fan drive tighten bolts to 23 N.m (17 ft. lbs.) torque.

2. Install the fan blade/viscous fan drive assembly to water pump shaft.

3. Install fan shroud.

4. Install air cleaner intake tube.

5. Connect negative battery cable.


2 of 3 2/26/2016 4:56 PM



3 of 3 2/26/2016 4:56 PM

Documents

The water pump on all engines is bolted directly to 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