Chrysler Full-Size Trucks 1997-2000 Repair Guide

Water Pump

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REMOVAL & INSTALLATION




CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Avoid physical contact with the coolant. Wear protective clothing and eye protection. Always drain coolant into a sealable container. Clean up spills as soon as possible. Coolant can be reused as long as it is reasonably clean and free of debris. If you suspect contamination, or if it is more than a couple of years old, it should be replaced.

Common Steps
  1. Disconnect the battery negative cable(s).
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Remove the lower radiator hose (except Diesel).
  8.  
  9. Disconnect the heater hose from the pump, if fitted.
  10.  


WARNING
Most cooling system hoses use "constant tension" hose clamps. When removing or installing, use a tool designed for servicing this type of clamp. The clamps are stamped with a letter or number on the tongue. If replacement is necessary, use only an OEM clamp with a matching ID.



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Fig. Heater hose pipe O-ring (arrow): twist gently when removing or installing; check condition; lubricate with coolant before installing


CAUTION
Always wear safety glasses when servicing contact tension clamps.

  1. Always use a new gasket when installing the water pump. Clean mating surfaces thoroughly before installation.
  2.  
  3. This would be a good time to replace radiator hoses. At least, inspect them carefully for aging or other damage.
  4.  
  5. If the heater hose pipe was removed, use thread sealant or equivalent on the pipe threads (if threaded), or lubricate any O-rings with coolant before installing.
  6.  
  7. Check the accessory belt routing against the plate in the engine compartment before starting engine.
  8.  
  9. Allow the engine to reach operating temperature and check for leaks.
  10.  

2.5L Engine

WARNING
The 2.5L engine has a reverse (CCW) rotating water pump. The letter "R" is stamped into the back of the pump impeller for ID purposes. Engines from previous model years may be equipped with a forward (CW) rotating water pump. Installing the wrong pump will cause engine damage. Check any replacement parts before installation.

  1. Carry out the "Common Steps" above.
  2.  
  3. Remove the power steering pump.
  4.  
  5. Remove the four water pump bolts and remove the pump. Note that one bolt is longer than the others. Be sure it is properly installed during installation.
  6.  

To install:

  1. Reverse the removal procedure.
  2.  
  3. Install the new gasket with the silicone bead facing the water pump.
  4.  
  5. Tighten mounting bolts to 22 ft. lbs. (30 Nm).
  6.  



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Fig. Reverse rotating water pump with impeller mark (1)-2.5L

3.9L, 4.7L, 5.2L, 5.9L, 8.0L Gasoline Engines
  1. Carry out the "Common Steps" above.
  2.  
  3. Remove the upper radiator hose.
  4.  
  5. Remove the fan and shroud assembly.
  6.  
  7. On engines except 4.7L, remove the four water pump pulley bolts and remove the pulley.
  8.  
  9. Remove the heater hose pipe mounting bolt, if fitted.
  10.  
  11. On engines except 4.7L, loosen the bypass hose clamp at the water pump.
  12.  
  13. Remove the seven water pump mounting bolts and, on the 4.7L, one nut.
  14.  


WARNING
Bolts may be of different lengths. Be sure to note their locations.

To install:

  1. Reverse the removal procedure.
  2.  
  3. The 8.0L engine uses an O-ring to seal. Use a new one and lubricate it with petroleum jelly before installation of the pump. Also, use sealant on the threads of the heater hose pipe, position the pipe as shown before installing the pump and tighten the nut to 12 ft. lbs. (16 Nm).
  4.  
  5. On pushrod engines, connect the bypass hose to the pump while installing it.
  6.  
  7. Tighten the bolts to 30 ft. lbs. (40 Nm) on pushrod engines, 40 ft. lbs. (54 Nm) on the 4.7L engine.
  8.  
  9. Spin pump to ensure the impeller is not rubbing against the timing chain case.
  10.  
  11. When installing the heater hose pipe, ensure that the slot in the pipe bracket is bearing against the mounting bolt. This will hold the pipe in as far as possible to prevent leaks.
  12.  
  13. Tighten pulley bolts to 20 ft. lbs. (27 Nm) on V-6 and V-8, 16 ft. lbs. (22 Nm) on the V-10.
  14.  



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Fig. Water pump mounting hardware-4.7L



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Fig. Use a prybar to keep the water pump from rotating while pulley bolts are removed



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Fig. Bypass hose clamp (arrow) must be tended to before removing the pump



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Fig. Water pump bolts differ in length; note check location before installation-3.9L, 5.2L, and 5.9L gasoline engine shown



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Fig. After removing the bolts, pull off the pump and place it in a safe location



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Fig. Make sure the heater hose fitting is positioned as shown -V-10 engine

Diesel
  1. Carry out the "Common Steps" above.
  2.  


NOTE
Removal of the radiator hoses is not required.

  1. Remove the wiring harness bolt from the water pump and arrange the harness out of the way.
  2.  
  3. Remove the water pump mounting bolts and remove the pump.
  4.  

To install:

  1. Use a new O-ring and lubricate it with petroleum jelly before installation.
  2.  
  3. Tighten mounting bolts to 18 ft. lbs. (24 Nm).
  4.  



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Fig. Water pump mounting-diesel

 
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