AutoZone 2004 GMC Truck Sierra 2500 4WD 6.0L SFI 8cyl | Repair Guides | Engine Cooling | Water Pump | Removal & Installation | AutoZone.com

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    2004 GMC Truck Sierra 2500 4WD 6.0L SFI 8cyl

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    Nissan Car Altima & Sentra 1999-06

    Removal & Installation

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    1.6L And 1.8L Engines



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Cylinder head front mounting bracket and loosen the water pump pulley bolts
       
      Engine drive belts
       
      Water pump pulley
       
      Coolant hoses from the water inlet and thermostat housing
       
      Water pump and thermostat housing
       

    6.  
    7. Remove all traces of gasket material from sealing surfaces.
    8.  

    To install:

    1. Apply a continuous bead of liquid sealer to the sealing surface of the thermostat housing. The sealant should be 0.079-0.118 in. (2-3mm) diameter.

      Click image to see an enlarged view

      Fig. Apply RTV sealant to the water pump sealing surface as shown-1.6L and 1.8L engines

    2.  
    3. Install or connect the following:

      Water pump. Torque the bolts to 56-73 inch lbs. (7-8 Nm).
       
      Pulley to the water pump and tighten the mounting bolts to 56-73 inch lbs. (7-8 Nm)
       
      Coolant hoses to the thermostat housing
       
      Drive belts and adjust as needed
       
      Cylinder head front mounting bracket
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system
    6.  
    7. Start the engine, check for leaks and repair if necessary.
    8.  

    1.6L Engines



    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Cylinder head front mounting bracket and loosen the water pump pulley bolts
       
      Engine drive belts
       
      Water pump pulley
       
      Coolant hoses from the water inlet and thermostat housing
       
      Water pump and thermostat housing
       

    6.  
    7. Remove all traces of gasket material from sealing surfaces.
    8.  

    To install:

    1. Apply a continuous bead of liquid sealer to the sealing surface of the thermostat housing. The sealant should be 0.079-0.118 in. (2-3mm) diameter.

      Click image to see an enlarged view

      Fig. Apply RTV sealant to the water pump sealing surface as shown-1.6L engine

    2.  
    3. Install or connect the following:

      Water pump. Torque the bolts to 56-73 inch lbs. (7-8 Nm)
       
      Pulley to the water pump and tighten the mounting bolts to 56-73 inch lbs. (7-8 Nm)
       
      Coolant hoses to the thermostat housing
       
      Drive belts and adjust as needed
       
      Cylinder head front mounting bracket
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system
    6.  
    7. Start the engine, check for leaks and repair if necessary.
    8.  

    1.8L Engine



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Cylinder head front mounting bracket and loosen the water pump pulley bolts
       
      Engine drive belts
       
      Water pump pulley
       
      Coolant hoses from the water inlet and thermostat housing
       
      Water pump and thermostat housing
       

    6.  
    7. Remove all traces of gasket material from sealing surfaces.
    8.  

    To install:

    1. Apply a continuous bead of liquid sealer to the sealing surface of the thermostat housing. The sealant should be 0.079-0.118 in. (2-3mm) diameter.
    2.  
    3. Install or connect the following:

      Water pump. Torque the bolts to 56-73 inch lbs. (7-8 Nm).
       
      Pulley to the water pump and tighten the mounting bolts to 56-73 inch lbs. (7-8 Nm)
       
      Coolant hoses to the thermostat housing
       
      Drive belts and adjust as needed
       
      Cylinder head front mounting bracket
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system
    6.  
    7. Start the engine, check for leaks and repair if necessary.
    8.  


      Click image to see an enlarged view

      Fig. Apply RTV sealant to the water pump sealing surface as shown- 1.8L engines


    2.0L Engine



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Right front wheel
       
      Engine side and front covers
       
      Loosen the water pump pulley bolts
       
      Drive belts
       
      3 lower water pump bolts and position a jackstand under the engine
       
      Front engine mount
       
      Water pump
       

    6.  
    7. Remove all traces of liquid gasket material from sealing surfaces.
    8.  

    To install:

    1. Apply a continuous bead of liquid sealer to the mating surface of the water pump. Sealer should be 0.079-0.118 in. (2-3mm) wide.
    2.  
    3. Install or connect the following:

      Water pump and torque the bolts to 12-15 ft. lbs. (16-21 Nm)
       
      Front engine mount and remove the engine support
       
      Water pump pulley. Torque the mounting bolts to 55-73 inch lbs. (6-8 Nm).
       
      Drive belts and adjust as needed
       
      Engine front and side cover
       
      Right front wheel
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the vehicle, check for leaks and repair if necessary.
    8.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Right front wheel
       
      Engine side and front covers
       
      Loosen the water pump pulley bolts
       
      Drive belts
       
      3 lower water pump bolts and position a jack stand under the engine
       
      Front engine mount
       
      Water pump
       

    6.  
    7. Remove all traces of liquid gasket material from sealing surfaces.
    8.  

    To install:

    1. Apply a continuous bead of liquid sealer to the mating surface of the water pump. Sealer should be 0.079-0.118 in. (2-3mm) wide.
    2.  
    3. Install or connect the following:

      Water pump and torque the bolts to 12-15 ft. lbs. (16-21 Nm)
       
      Front engine mount and remove the engine support
       
      Water pump pulley. Torque the mounting bolts to 55-73 inch lbs. (6-8 Nm)
       
      Drive belts and adjust as needed
       
      Engine front and side cover
       
      Right front wheel
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the vehicle, check for leaks and repair if necessary.
    8.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Right front wheel
       
      Engine side and front covers
       
      Loosen the water pump pulley bolts
       
      Drive belts
       
      3 lower water pump bolts and position a jackstand under the engine
       
      Front engine mount
       
      Water pump
       

    6.  
    7. Remove all traces of liquid gasket material from sealing surfaces.
    8.  

    To install:

    1. Apply a continuous bead of liquid sealer to the mating surface of the water pump. Sealer should be 0.079-0.118 in. (2-3mm) wide.
    2.  
    3. Install or connect the following:

      Water pump and torque the bolts to 12-15 ft. lbs. (16-21 Nm)
       
      Front engine mount and remove the engine support
       
      Water pump pulley. Torque the mounting bolts to 55-73 inch lbs. (6-8 Nm).
       
      Drive belts and adjust as needed
       
      Engine front and side cover
       
      Right front wheel
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the vehicle, check for leaks and repair if necessary.
    8.  

    2.4L Engine



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Right lower splash cover
       
      Alternator and A/C compressor
       
      Coolant tube
       
      Water pump
       

    6.  


    NOTE
    Do not disconnect the air conditioning compressor lines. Unbolt the compressor and lay it off to the side.


    NOTE
    The mounting bolts are different sizes and must be reinstalled in the correct location; therefore it is a good idea to arrange the bolts so that they can be easily identified during installation.



    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-2.4L engine

    To install:

    1. Be sure all gasket surfaces are clean and properly apply a continuous bead of silicone sealer to the pump.
    2.  
    3. Install or connect the following:

      Water pump and torque the 6mm bolts to 57-66 inch lbs. (6-8 Nm) and the 8mm bolts to 12-14 ft. lbs. (16-19 Nm)
       
      Coolant tube
       
      Alternator and A/C compressor
       
      Right side lower splash shield
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the engine, check for leaks and repair if necessary.
    8.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:
      NOTE
      Do not disconnect the air conditioning compressor lines. Unbolt the compressor and lay it off to the side.


      NOTE
      The mounting bolts are different sizes and must be reinstalled in the correct location; therefore it is a good idea to arrange the bolts so that they can be easily identified during installation.



      Negative battery cable
       
      Right lower splash cover
       
      Alternator and A/C compressor
       
      Coolant tube
       
      Water pump
       



      Click image to see an enlarged view

      Fig. Exploded view of the water pump assembly-2.4L engine

    6.  

    To install:

    1. Be sure all gasket surfaces are clean and properly apply a continuous bead of silicone sealer to the pump.
    2.  
    3. Install or connect the following:

      Water pump and torque the 6mm bolts to 57-66 inch lbs. (6-8 Nm) and the 8mm bolts to 12-14 ft. lbs. (16-19 Nm)
       
      Coolant tube
       
      Alternator and A/C compressor
       
      Right side lower splash shield
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the engine, check for leaks and repair if necessary.
    8.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:
      NOTE
      Do not disconnect the air conditioning compressor lines. Unbolt the compressor and lay it off to the side.


      NOTE
      The mounting bolts are different sizes and must be reinstalled in the correct location; therefore it is a good idea to arrange the bolts so that they can be easily identified during installation.



      Negative battery cable
       
      Right lower splash cover
       
      Alternator and A/C compressor
       
      Coolant tube
       
      Water pump
       



      Click image to see an enlarged view

      Fig. Exploded view of the water pump assembly-2.4L engine

    6.  

    To install:

    1. Be sure all gasket surfaces are clean and properly apply a continuous bead of silicone sealer to the pump.
    2.  
    3. Install or connect the following:

      Water pump and torque the 6mm bolts to 57-66 inch lbs. (6-8 Nm) and the 8mm bolts to 12-14 ft. lbs. (16-19 Nm)
       
      Coolant tube
       
      Alternator and A/C compressor
       
      Right side lower splash shield
       
      Negative battery cable
       

    4.  
    5. Fill the cooling system.
    6.  
    7. Start the engine, check for leaks and repair if necessary.
    8.  

    2.5L Engine



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Disconnect the negative battery cable
    6.  
    7. On Altima remove or disconnect the following:

      Upper and lower engine covers
       
      Coolant reservoir
       
      Power Distribution Module (PDM) and move aside
       
      Passenger front wheel
       
      Engine ground
       

    8.  
    9. On all models remove or disconnect the following:

      Drive belt
       
      Radiator hose
       
      Alternator
       
      Water pump
       

    10.  


      Click image to see an enlarged view

      Fig. Exploded view of the water pump assembly-2.5L engine


    To install:

    1. Be sure all gasket surfaces are clean and properly apply a continuous bead of silicone sealer to the pump.
    2.  
    3. Install or connect the following:

      Water pump and torque the bolts to 16-20 ft. lbs. (21-28 Nm)
       

    4.  
    5. Reverse the removal procedure to complete installation.
    6.  
    7. Connect the negative battery cable.
    8.  
    9. Fill the cooling system.
    10.  
    11. Start the engine, check for leaks and repair if necessary.
    12.  

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Disconnect the negative battery cable
    6.  
    7. On Altima remove or disconnect the following:

      Upper and lower engine covers
       
      Coolant reservoir
       
      Power Distribution Module (PDM) and move aside
       
      Passenger front wheel
       
      Engine ground
       

    8.  
    9. Remove or disconnect the following:

      Drive belt
       
      Radiator hose
       
      Alternator
       
      Water pump

      Click image to see an enlarged view

      Fig. Exploded view of the water pump assembly-2.5L engine

       

    10.  

    To install:

    1. Be sure all gasket surfaces are clean and properly apply a continuous bead of silicone sealer to the pump.
    2.  
    3. Install or connect the following:

      Water pump and torque the bolts to 16-20 ft. lbs. (21-28 Nm)
       

    4.  
    5. Reverse the removal procedure to complete installation.
    6.  
    7. Connect the negative battery cable.
    8.  
    9. Fill the cooling system.
    10.  
    11. Start the engine, check for leaks and repair if necessary.
    12.  

    3.0L & 3.5L Engines





    Click image to see an enlarged view

    Fig. Water pump and timing cover assembly-3.0L engine



    Click image to see an enlarged view

    Fig. Water pump and timing cover assembly-3.5L engine-Altima and Maxima

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Position a jack under the oil pan for support. Be sure to place a block of wood on the jack for protection to the engine parts.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Right side engine mount and bracket
       
      Drive belts and the idler pulley bracket
       
      Chain tensioner cover and the water pump cover
       

    8.  
    9. Push the timing chain tensioner sleeve and apply a stopper pin so it does not return.

      Timing chain tensioner assembly
       
      3 bolts that secure the water pump
       

    10.  
    11. Rotate the crankshaft 20 degrees counterclockwise to provide timing chain slack.
    12.  
    13. Put M8 bolts in 2 M8 threaded holes of the water pump.
    14.  
    15. Tighten each bolt by turning alternately1212
    16.  
    17. Lift up the water pump and remove it.
    18.  
    19. When removing the water pump, do not allow the water pump gear to hit the timing chain.
    20.  
    21. Remove and discard the O-rings from the water pump.
    22.  
    23. Clean all traces of liquid gasket from the water pump and covers.
    24.  

    To install:

    1. Install or connect the following:

      Water pump using new O-rings to the engine block. Torque the 3 water pump mounting bolts evenly to 62-89 inch lbs. (7-10 Nm) for 3.0L engines, or to 75-95 inch lbs. (8.5-10.7 Nm) for 3.5L engines.
       

    2.  
    3. Rotate the crankshaft pulley to its original position by turning it 20 degrees clockwise.

      Timing chain tensioner and torque the bolts to 75-89 inch lbs. (9-10 Nm)
       

    4.  
    5. Remove the stopper pin from the timing chain tensioner.
    6.  
    7. Apply a continuous 0.091-0.130 in. (2.3-3.3mm) bead of liquid sealant to the mating surfaces of the timing chain tensioner and water pump covers.

      Timing chain tensioner and water pump covers to the engine block. Torque the bolts to 89-108 inch lbs. (10-13 Nm).
       
      Drive belts and the idler pulley bracket
       
      Right side engine mounting bracket and the engine mount
       
      Negative battery cable
       

    8.  
    9. Remove the jack from under the engine and install the drain plugs to the cylinder block.
    10.  
    11. Fill the cooling system.
    12.  
    13. Start the engine, check for leaks and repair if necessary.
    14.  

    3.0L Engine





    Click image to see an enlarged view

    Fig. Water pump and timing cover assembly-3.0L engine

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Position a jack under the oil pan for support. Be sure to place a block of wood on the jack for protection to the engine parts.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Right side engine mount and bracket
       
      Drive belts and the idler pulley bracket
       
      Chain tensioner cover and the water pump cover
       

    8.  
    9. Push the timing chain tensioner sleeve and apply a stopper pin so it does not return.
    10.  
    11. Remove or disconnect the following:

      Timing chain tensioner assembly
       
      3 bolts that secure the water pump
       

    12.  
    13. Rotate the crankshaft 20 degrees counterclockwise to provide timing chain slack.
    14.  
    15. Put M8 bolts in 2 M8 threaded holes of the water pump.
    16.  
    17. Tighten each bolt by turning alternately 1 / 2 turn until they reach the timing chain rear case. Be sure to turn each bolt 1 / 2 turn at a time to prevent damage.
    18.  
    19. Lift up the water pump and remove it.
    20.  
    21. When removing the water pump, do not allow the water pump gear to hit the timing chain.
    22.  
    23. Remove and discard the O-rings from the water pump.
    24.  
    25. Clean all traces of liquid gasket from the water pump and covers.
    26.  

    To install:

    1. Install or connect the following:

      Water pump using new O-rings to the engine block. Torque the 3 water pump mounting bolts evenly to 62-89 inch lbs. (7-10 Nm)
       

    2.  
    3. Rotate the crankshaft pulley to its original position by turning it 20 degrees clockwise.
    4.  
    5. Install or connect the following:

      Timing chain tensioner and torque the bolts to 75-89 inch lbs. (9-10 Nm)
       

    6.  
    7. Remove the stopper pin from the timing chain tensioner.
    8.  
    9. Apply a continuous 0.091-0.130 in. (2.3-3.3mm) bead of liquid sealant to the mating surfaces of the timing chain tensioner and water pump covers.

      Timing chain tensioner and water pump covers to the engine block. Torque the bolts to 89-108 inch lbs. (10-13 Nm)
       
      Drive belts and the idler pulley bracket
       
      Right side engine mounting bracket and the engine mount
       
      Negative battery cable
       

    10.  
    11. Remove the jack from under the engine and install the drain plugs to the cylinder block.
    12.  
    13. Fill the cooling system.
    14.  
    15. Start the engine, check for leaks and repair if necessary.
    16.  

    3.5L Engine





    Click image to see an enlarged view

    Fig. View of water pump and components


    CAUTION
    When removing water pump assembly, be careful not to get coolant on drive belt.


    CAUTION
    Water pump cannot be disassembled and should be replaced as a unit.


    CAUTION
    After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester.

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Disconnect the negative battery cable.
    6.  
    7. Remove or disconnect the following:

      Engine coolant reservoir tank
       
      IPDM/ER aside
       
      RH wheel and tire and the splash shield
       
      Drive belts
       
      Idler pulley, then the power steering and generator adjusting bars
       
      Support engine and remove the front engine insulator and bracket

      Click image to see an enlarged view

      Fig. Identifying chain tensioner cover, water pump cover and water drain plug

       
      Water drain plug on water pump side of cylinder block
       
      Chain tensioner cover and water pump cover
       

    8.  
    9. Remove timing chain tensioner assembly by performing the following:
      NOTE
      An allen wrench (2.5 mm (0.98 inch) is used for a stopper pin as an example.


      CAUTION
      Be careful not to drop bolts inside chain case.



      Pull the lever down and release the plunger stopper tab

      Click image to see an enlarged view

      Fig. Inserting the stopper pin into the tensioner body hole

       
      Insert the stopper pin into the tensioner body hole to hold the lever and keep the stopper tab released.
       



      Insert the plunger into the tensioner body by pressing the timing chain slack guide.
       
      Keep the slack guide pressed and hold the plunger in by pushing the stopper pin deeper through the lever and into the tensioner body hole
       
      Make a gap between water pump gear and timing chain, by turning the crankshaft pulley approximately 20 degrees clockwise.
       



      Click image to see an enlarged view

      Fig. Removing the chain tensioner



      Click image to see an enlarged view

      Fig. Removing the three water pump bolts and turning crankshaft pulley

    10.  
    11. Remove chain tensioner.
    12.  
    13. Remove the three water pump bolts. Make a gap between water pump gear and timing chain, by turning crankshaft pulley counterclockwise until timing chain loosens on water pump sprocket.

      Click image to see an enlarged view

      Fig. Screwing M8 bolts into water pump upper and lower bolt holes

    14.  
    15. Screw M8 bolts [pitch: 1.25 mm (0.49 in) length: approx. 50 mm (1.97 in)] into water pump-s upper and lower bolt holes until they reach the timing chain case. Then, alternately tighten each bolt for a half turn, and pull out the water pump.
    16.  
    17. Pull straight out while preventing vane from contacting socket in installation area.
    18.  
    19. Remove water pump without causing sprocket to contact timing chain.
    20.  
    21. Remove M8 bolts and O-rings from water pump.
    22.  

    To install:

    Click image to see an enlarged view

    Fig. Installing O-rings to water pump



    Click image to see an enlarged view

    Fig. Installing water pump bolts

    1. Install new O-rings to water pump.
    2.  
    3. Apply engine oil and coolant to the O-rings. Locate the O-ring with white paint mark to engine front side.
      CAUTION
      Do not allow cylinder block to interfere with the O-rings when installing the water pump.

    4.  
    5. To install the water pump, perform the following:

      Check that timing chain and water pump sprocket are engaged.
       
      Insert water pump by tightening bolts alternately and evenly.
       
      Torque water pump bolts to: 75-95 inch lbs. (8.5-10.7 Nm).
       

    6.  
    7. Remove dust and foreign material completely from backside of chain tensioner and from installation area of rear timing chain case.
    8.  
    9. Turn the crankshaft pulley approximately 20 degrees clockwise so that the timing chain on the timing chain tensioner side is loose.
      NOTE
      When installing the timing chain tensioner, engine oil should be applied to the oil hole and tensioner.

    10.  
    11. Install the timing chain tensioner and torque the bolts to: 62-82 inch lbs. (7-9.3 Nm).
    12.  
    13. Remove the stopper pin.
    14.  
    15. Before installing chain tensioner cover and water pump cover, remove all traces of sealant from mating surface of water pump cover and chain tensioner cover using a scraper. Also remove traces of sealant from the mating surface of the front cover.
    16.  
    17. Apply a continuous bead of RTV Silicone Sealant or equivalent, to mating surface of chain tensioner cover and water pump cover.
    18.  
    19. Install water drain plug on water pump side of cylinder block
    20.  
    21. Install idler pulley and idler pulley bolts. Torque bolts to: 21 ft. lbs (28 Nm).
    22.  
    23. To complete installation, reverse remaining removal procedure.
      NOTE
      Refill engine coolant. After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioner. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

    24.  

     
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