Astro, Safari 1997-2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    On some engines, the pump retaining bolts will vary in size and thread. Be sure to note the positioning of all bolts during removal to assure proper installation.



    Air intake assembly
     
    Mass Air Flow (MAF) sensor
     
    Upper fan shroud
     
    Drive belt
     
    Fan and clutch assembly
     
    Water pump pulley using special tool J 41240
     
    Coolant hoses
     
    Water pump
     

  8.  
  9. Clean gasket mounting surface.

    Click image to see an enlarged view

    Fig. Removing the water pump pulley using special tool J-41240



    Click image to see an enlarged view

    Fig. Water pump mounting-2002 shown

  10.  

To install:

  1. Install or connect the following:

    Water pump. Torque bolts to 33 ft. lbs. (45 Nm).
     
    Coolant hoses using new clamps
     
    Water pump pulley. Tighten bolts to 18 ft. lbs. (25 Nm).
     
    Fan and clutch assembly
     
    Drive belt
     
    Fan shroud
     
    MAF sensor
     
    Air intake assembly
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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