Jeep Wagoneer/Commando/Cherokee 1984-1998

Water Pump

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Removal & Installation



2.1L Diesel Engine

See Figures 1 and 2

  1. Disconnect the negative battery cable. Drain the engine coolant.
  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. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the coolant hose from the water pump.
  2.  
  3. Remove the drive belts.
  4.  



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Fig. Fig. 1: Water pump mounting on the diesel engine

  1. Remove the fan and hub assembly.
  2.  
  3. It is not necessary to remove the timing belt tensioner. Use a long strap and clip in order to retain the timing belt tensioner plunger in place.
  4.  



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Fig. Fig. 2: Use a strap to hold the tensioner in place

  1. Remove the water pump retaining bolts. Remove the water pump assembly from the vehicle.
  2.  

To install:
  1. Clean the mating surfaces of all gasket material.
  2.  
  3. Do not use sealer on the new gasket. Position the gasket and pump on the engine and install the bolts. Tighten the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Re-tension the timing belt.
  6.  
  7. Install the fan and hub, drive belts and coolant hoses.
  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the battery.
  12.  

2.5L, 2.8L and 4.0L Engines

See Figures 3, 4 and 5

Some vehicles use a serpentine drive belt and have a reverse rotating water pump coupled with a viscous fan drive assembly. The components are identified by the words REVERSE stamped on the cover of the viscous drive and on the inner side of the fan. The word REV is also cast into the body of the water pump.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the hoses at the pump.
  6.  
  7. Remove the drive belts.
  8.  
  9. Remove the power steering pump bracket.
  10.  
  11. Remove the fan and shroud.
  12.  
  13. If equipped, remove the idler pulley to gain clearance for pump removal.
  14.  
  15. Unbolt and remove the pump.
  16.  



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Fig. Fig. 3: Remove the power steering pump and bracket, then move it aside



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Fig. Fig. 4: Disconnect the radiator hose from the water pump



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Fig. Fig. 5: Remove the bolts securing the pump, then remove it from the engine

To install:
  1. Clean the mating surfaces thoroughly.
  2.  
  3. Using a new gasket, install the pump and tighten the bolts to 13 ft. lbs. (18 Nm).
  4.  
  5. If removed, install the idler pulley.
  6.  
  7. Reconnect the hoses at the pump and install accessory drive belt.
  8.  
  9. Install the power steering pump bracket. Install the fan and shroud.
  10.  
  11. Adjust the belt tension and fill the cooling system to the correct level.
  12.  
  13. Operate the engine with the heater control valve in the HEAT position until the thermostat opens to purge air from the system. Check coolant level and fill as required.
  14.  

5.2L and 5.9L Engines

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Open the radiator valve and drain the cooling system.
  4.  
  5. Remove the cooling fan and shroud as an assembly.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Remove the water pump pulley from the hub.
  10.  
  11. Disconnect the hoses from the water pump.
  12.  
  13. Loosen the heater hose coolant return tube mounting bolt and nut and remove the tube. Discard the O-ring.
  14.  



Click image to see an enlarged view

Fig. Fig. 6: Water pump mounting bolt locations

  1. Remove the water pump mounting bolts.
  2.  
  3. Loosen the clamp at the water pump end of the bypass hose. Slip the bypass hose from the water pump while removing the pump from the engine. Discard the gasket.
  4.  

To install:
  1. Clean all gasket mating surfaces.
  2.  
  3. Guide the water pump and new gasket into position while connecting the bypass hose to the pump. Tighten the water pump bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install the bypass hose clamp.
  6.  
  7. Spin the water pump to ensure the pump impeller does not rub against the timing chain cover.
  8.  
  9. Coat a new O-ring with coolant and install it to the heater hose coolant return tube.
  10.  
  11. Install the coolant return tube to the engine. Ensure the slot in the tube bracket is bottomed to the mounting bolt. This will properly position the return tube.
  12.  
  13. Connect the radiator hose to the water pump.
  14.  
  15. Connect the heater hose and clamp to the return tube.
  16.  
  17. Install the water pump pulley and tighten the bolts to 20 ft. lbs. (27 Nm).
  18.  
  19. Install the accessory drive belt.
  20.  
  21. Install the cooling fan and shroud.
  22.  
  23. Fill the cooling system.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Start the engine and check for leaks.
  28.  

 
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