Chrysler Full-Size Trucks 1989-1996 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



2.5L Engine

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  

When removing or installing the constant tension hose clamps from vehicles so equipped, use only the correct clamp tool, such as the Snap-On No. HPC-20, or equivalent.

  1. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

  1. If the vehicle is equipped with air conditioning, remove the compressor from the bracket and position it to the side.
  2.  



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Fig. Fig. 1: Unbolt the water pump at the locations shown-2.5L engine

  1. Raise the vehicle and support safely, if necessary and remove the alternator and bracket. Remove the pulley from the water pump.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the water pump assembly including the gasket

  1. Disconnect the lower radiator hose and heater hose from the water pump.
  2.  
  3. Remove the water pump housing attaching screws and remove the assembly from the vehicle. Discard the O-ring.
  4.  
  5. Remove the water pump from the housing.
  6.  

To install:
  1. Clean the mating surfaces prior to sealing the water pump.
  2.  

This component is subjected to constant high pressure from hot fluid and must be sealed correctly or it will leak.

  1. Using a new gasket or silicone sealer, install the water pump to the housing.
  2.  
  3. Install a new O-ring to the housing and install to the engine. Tighten the bolts to 21 ft. lbs. (30 Nm).
  4.  
  5. Install the water pump pulley. Connect the radiator hose and heater hose to the water pump.
  6.  
  7. Install all items removed to gain access to the water pump and adjust the belt(s).
  8.  
  9. Remove the hex-head plug on the top of the thermostat housing (some carbureted engines have a vacuum switching valve at that location). Fill the radiator with coolant until the coolant comes out the plug hole. Install the plug or valve and continue to fill the radiator.
  10.  
  11. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely and check for leaks.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

3.9L Engine

See Figures 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the hoses from the water pump assembly

When removing or installing the constant tension hose clamps from vehicles so equipped, use only the correct clamp tool, such as the Snap-On No. HPC-20, or equivalent.



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Fig. Fig. 4: Once all the hoses are detached, unbolt the water pump from the engine

  1. Remove the radiator and lower hose.
  2.  



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Fig. Fig. 5: Separate the water pump and set it aside

  1. Remove the fan blade, spacer or viscous drive unit, pulley, bolts and shroud together. Remove the air pump
  2.  

belt and power steering pump belt.

Click image to see an enlarged view

Fig. Fig. 6: Scrape away all old gasket material-take care not to gouge the surface

Do not place the viscous fan in an upright position because the silicone fluid in the drive could drain into the bearing and contaminate its lubricant.

  1. Loosen the alternator mounting bolts and remove the alternator/air conditioning or idler pulley belt(s).
  2.  
  3. Remove the alternator bracket. This bracket also supports the air conditioning compressor or idler pulley, which will remain supported by its rear mount.
  4.  



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Fig. Fig. 7: Remove the V-belt(s) to access the water pump-V6 and V8 engines

  1. Remove the air pump. Remove the air pump bracket and unbolt the power steering pump bracket with the pump still attached and position it out of the way.
  2.  
  3. Disconnect the heater hose and bypass hose.
  4.  
  5. Remove the air conditioning compressor pulley and field coil assembly, if necessary to remove the water pump to compressor front mount bolts and bracket.
  6.  
  7. Remove the remaining pump retaining bolts (if any) and remove the pump from the engine.
  8.  

To install:
  1. Clean and dry the pump mating surfaces. Install a new by-pass hose to the engine.
  2.  

This component is subjected to constant high pressure from hot fluid and must be sealed correctly or it will leak.

  1. Install a new gasket and install the water pump to the engine.
  2.  
  3. Install any bolts that do not retain a bracket.
  4.  
  5. Tighten the bypass hose clamps. Install the heater hose.
  6.  
  7. Install the water pump to compressor front mount bolts and bracket, if it was removed.
  8.  
  9. Install all remaining brackets and components that were removed. Torque all water pump retaining bolts that do not go through adjusting slots to 30 ft. lbs. (41 Nm).
  10.  
  11. Install the air conditioning compressor pulley and field coil assembly, if it was removed. Install and adjust the alternator/air conditioning or idler belt(s). If applicable, place the remaining belts over their components.
  12.  
  13. Install the fan blade, spacer or viscous drive unit, pulley and bolts along with the shroud.
  14.  
  15. Install the radiator, lower hose and shroud.
  16.  
  17. Adjust the belt(s) and tighten the remaining water pump retaining bolts to 30 ft. lbs. (41 Nm).
  18.  
  19. Fill the radiator with coolant. This cooling system is self-bleeding, so system bleeding is not required.
  20.  
  21. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely and check for leaks.
  22.  
  23. Once the vehicle has cooled, recheck the coolant level.
  24.  

5.2L and 5.9L Engines

See Figure 8

  1. Remove the radiator.
  2.  

When removing or installing the constant tension hose clamps from vehicles so equipped, use only the correct clamp tool, such as the Snap-On No. HPC-20, or equivalent.

  1. Loosen all accessories that are belt driven and remove the belt(s).
  2.  
  3. On engines without air conditioning, remove the alternator bracket attaching bolts and tie the alternator and bracket out of the way.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the V-belts (earlier models) or serpentine belt (later models) to access the water pump-heavy duty 5.9L V8 models

  1. On engines with air conditioning, remove the idler pulley assembly, alternator, and adjusting bracket.
  2.  
  3. Remove the fan blade, spacer (or fluid unit), pulley, and bolts as an assembly.
  4.  

To prevent silicone fluid from draining into the drive bearing and ruining the lubricant, do not place the thermostatic fan drive unit with the shaft pointing downward.

  1. Disconnect all hoses from the water pump.
  2.  
  3. Remove the air conditioning compressor front mounting bolts.
  4.  
  5. Remove the water pump-to-compressor front bracket bolts and the bracket. Remove the water pump.
  6.  

Do not disconnect any refrigerant lines from the compressor.

To install:

This component is subjected to constant high pressure from hot fluid and must be sealed correctly or it will leak.

  1. Clean the mating surfaces prior to sealing the water pump.
  2.  
  3. Install the water pump on the engine. Use a new gasket coated with sealer.
  4.  
  5. Install the water-pump-to-compressor front bracket mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  6.  
  7. Install the air conditioning compressor front mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  8.  
  9. Reconnect all hoses to the water pump.
  10.  
  11. Install the fan blade, spacer (or fluid unit), pulley, and bolts as an assembly.
  12.  
  13. On engines with air conditioning, install the idler pulley assembly, alternator, and adjusting bracket.
  14.  
  15. On engines without air conditioning, install the alternator and bracket.
  16.  
  17. Install the drive belt(s).
  18.  
  19. Install the radiator. Fill the cooling system and adjust the tension of the drive belt(s).
  20.  

8.0L Engine

See Figures 9, 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the washer bottle from the fan shroud and disconnect the fan shroud but do not remove it from the radiator.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: Remove/install the water pump bolts shown-V10 engine



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Fig. Fig. 10: Details of the water pump O-ring seal-V10 engine

  1. Remove the upper radiator hose from the radiator.
  2.  

When removing or installing the constant tension hose clamps from vehicles so equipped, use only the correct clamp tool, such as the Snap-On No. HPC-20, or equivalent.

Click image to see an enlarged view

Fig. Fig. 11: Make sure the heater hose is fitted exactly as shown for correct mounting-V10 engine

  1. Remove the fan blade, spacer (or fluid unit), pulley, and bolts as an assembly.
  2.  

To prevent silicone fluid from draining into the drive bearing and ruining the lubricant, do not place the thermostatic fan drive unit with the shaft pointing downward.

  1. Loosen all accessories that are belt driven and remove the belt.
  2.  
  3. Remove the four water pump pulley-to-water pump hub bolts and remove the pulley from the vehicle.
  4.  
  5. Remove the lower radiator hose from the water pump.
  6.  
  7. Remove the heater hose at the water pump fitting.
  8.  
  9. Remove the seven water pump mounting bolts.
  10.  
  11. Loosen the clamp at the water pump end of the bypass hose. Slip the hose from the water pump while removing the pump from the vehicle. Do not remove the clamp from the bypass hose.
  12.  
  13. Discard the water pump-to-timing chain/case/cover O-ring seal.
  14.  
  15. Remove the heater hose fitting from the water pump if the pump replacement is necessary. Note the position (direction) of the fitting before removal. The fitting must be installed in the same position.
  16.  

Do not disconnect any refrigerant lines from the compressor.

To install:

This component is subjected to constant high pressure from hot fluid and must be sealed correctly or it will leak.

  1. Clean the mating surfaces prior to sealing the water pump.
  2.  
  3. Install the water pump on the engine. Use a new gasket coated with sealer.
  4.  
  5. Install the water-pump-to-compressor front bracket mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  6.  
  7. If a new pump has been installed, then install the heater hose fitting to the pump. Tighten the fitting to 144 inch lbs. (16 Nm). After the fitting is tightened, position it as shown in the drawing. When positioning the fitting, do not back it off (rotate counterclockwise). Use a suitable Teflon® containing thread sealant. Refer to the directions on the package.
  8.  
  9. Clean the O-ring groove and install a new O-ring.
  10.  
  11. Apply a small amount of petroleum jelly to the O-ring to help it stay in place on the water pump.
  12.  
  13. Install the water pump to the engine as follows:
    1. Guide the pump fitting bypass hose as the hose is being installed.
    2.  
    3. Install the water pump and tighten them to 30 ft. lbs. (40 Nm).
    4.  

  14.  
  15. Position the bypass clamp on the hose.
  16.  
  17. Spin the water pump to be sure that the pump impeller does not rub against the timing chain case/cover.
  18.  
  19. Connect the radiator lower hose to the to the water pump.
  20.  
  21. Connect the heater hose and hose clamp to the heater hose fitting.
  22.  
  23. Install the water pump pulley. Tighten the bolts to 16 ft. lbs. (22 Nm). Place a prybar between the water pump pulley bolts to prevent the pulley from relaxing.
  24.  
  25. Install the serpentine belt.
  26.  
  27. Position the fan shroud assembly and fan blade/viscous fan drive assembly as a complete unit.
  28.  
  29. Install the fan shroud to the radiator. Tighten the bolts to 50 inch lbs. (6 Nm).
  30.  
  31. Install the fan blade and viscous fan drive to the water pump shaft.
  32.  
  33. Fill the cooling system, connect the negative battery cable and check for leaks.
  34.  

Diesel Engine

See Figure 12

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant.
  4.  
  5. Use a 3 / 8 in. drive breaker bar to lift the belt tensioner and remove the belt.
  6.  



Click image to see an enlarged view

Fig. Fig. 12: Always install a new O-ring in the diesel water pump

  1. Remove the two water pump retaining bolts and remove the pump from the engine.
  2.  
  3. Remove the O-ring from the pump groove.
  4.  

To install:
  1. Clean the O-ring groove and install a new O-ring.
  2.  
  3. Clean the pump mating surfaces and install the pump to the engine.
  4.  
  5. Tighten the mounting bolts to 18 ft. lbs. (24 Nm). Fill the radiator with coolant.
  6.  
  7. Install the drive belt.
  8.  
  9. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely and check for leaks.
  10.  
  11. Once the vehicle has cooled, recheck the coolant level.
  12.  

 
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