Installation

1. Clean gasket mating surfaces.

Water Pump Bolts-3.9L V-6 Or 5.2/5.9L V-8 Gas Engines-Typical:

2. 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.
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.

Coolant Return Tube-3.9L V-6 Or 5.2/5.9L V-8 LDC-Gas Engines:

Coolant Return Tube-5.9L HDC-Gas Engine:

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 will properly position return tube.
7. Connect radiator lower hose to water pump.
8. Connect heater hose and hose clamp to coolant return tube.
9. 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.
10. Relax tension from automatic belt tensioner. Install drive belt.

Belt Routing-3.9L V-6 Or 5.2/5.9L V-8 LDC-Gas Engines:

Belt Routing-5.9L HDC-Gas Engine-With A/C:

Belt Routing-5.9L HDC-Gas Engine-Without A/C:

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 images for correct belt routing. The correct belt with correct length must be used.

11. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit.
12. Install fan shroud.
13. Install fan blade/viscous fan drive assembly to water pump shaft.
14. Fill cooling system.
15. Connect negative battery cable.
16. Start and warm the engine. Check for leaks.