Water Pump: Service and Repair

WATER PUMP

REMOVAL
8.3L ENGINE

NOTE: The water pump on all models can be removed without discharging the air conditioning system (if equipped).

The water pump on all gas powered engines is bolted directly to the engine timing chain case/ cover.

On the 8.0L V-10 engine, a rubber O-ring (instead of 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 conditions of the thermal viscous fan drive.

1. Disconnect negative battery cable from battery.
2. Drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.





3. Remove windshield washer reservoir tank from radiator fan shroud.
4. Remove the four fan shroud mounting bolts at the radiator. Do not attempt to remove shroud from vehicle at this time.

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. ALWAYS 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 original equipment clamp with a matching number or letter.

5. Remove radiator upper hose at radiator.
6. Remove accessory drive belt.
7. Remove the radiator lower hose at water pump.
8. Remove heater hose at water pump fitting.





9. Remove the seven water pump mounting bolts.
10. Loosen the clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while removing pump from vehicle. Do not remove the clamp from the bypass hose.





11. Discard the water pump-to-timing chain/case cover O-ring seal.
12. Remove the heater hose fitting from water pump if pump replacement is necessary. Note position (direction) of fitting before removal. Fitting must be re-installed to same position.

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

CLEANING
Clean the gasket mating surface. Use caution not to damage the gasket sealing surface.

INSPECTION
Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover.

INSTALLATION





1. If water pump is being replaced, install the heater hose fitting to the pump. Tighten fitting to 16 Nm (144 inch lbs.) torque. After fitting has been torqued, position fitting as shown in. When positioning fitting, do not back off (rotate counterclockwise). Use a sealant on the fitting such as Mopar(R) Thread Sealant With Teflon. Refer to the directions on the package.

CAUTION: This heater hose fitting must be installed to pump before pump is installed to engine.

2. Clean the O-ring mating surfaces at rear of water pump and front of timing chain/case cover.
3. Apply a small amount of petroleum jelly to O-ring. This will help retain O-ring to water pump.
4. Install water pump to engine as follows: Guide water pump fitting into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque.
5. Position bypass hose clamp to bypass hose.
6. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
7. Connect radiator lower hose to water pump.
8. Connect heater hose and hose clamp to heater hose fitting.
9. Install drive belt.
10. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit.
11. Install fan shroud to radiator. Tighten bolts to 6 Nm (50 inch lbs.) torque.
12. Install fan blade/viscous fan drive assembly to water pump shaft.
13. Fill cooling system.
14. Connect negative battery cable.
15. Start and warm the engine. Check for leaks.