Water Pump: Service and Repair

Removal Procedure





1. Disconnect both negative battery cables from the batteries,
2. Drain the engine cooling system.
3. Remove the air cleaner assembly from the vehicle.
4. Remove the air intake duct from the turbocharger.
5. Remove the surge tank from the vehicle.
6. Remove the upper fan shroud from the radiator.

7. Remove the fan clutch from the water pump pulley.
8. Remove the drive belt from the vehicle. in Engine Mechanical - 6.5L.





9. Remove the water pump pulley mounting bolts.
10. Remove the water pump pulley from the water pump.





11. Disconnect the radiator outlet hose from the water pump.





12. Disconnect the by-pass hose from the water pump.
13. Remove the generator mounting bracket from the engine block.
14. Remove the engine lift bracket from the engine block. in Engine Mechanical - 6.5L.





15. Remove the water pump mounting bolts.
16. Remove the water pump assembly from the engine front cover.





17. Remove the bolts from the back of the water pump backing plate.
18. Remove the water pump from the backing plate.
19. Remove the gasket from the water pump backing plate.
20. Clean and inspect the gasket sealing surfaces of the engine front cover and water pump backing plate.
21. Clean all the water pump mounting bolts.

Installation Procedure

Important: When servicing the water pump assembly, do not apply any sealant to the water pump gasket. The water pump gasket is manufactured with the proper amount of sealant printed on it.





1. Install the water pump gasket.





2. Apply a bead of anaerobic sealer GM P/N 1052942 or the equivalent to the water pump plate.
3. Install the water pump to the backing plate.
4. Apply high temperature thread adhesive GM P/N 12345493 or equivalent, to the bolt threads.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the mounting bolts behind the water pump plate.
^ Tighten the water pump plate bolts to 28 Nm (20 ft. lbs.).





6. Install the water pump and backing plate to the engine. The sealer must be wet to the touch when installing the plate.
7. Apply Teflon Pipe Sealant GM P/N 123456004 or equivalent to the thread of the bolts and the studs.
8. Install the bolts and the studs.
^ Tighten the water pump to the front cover bolts to 42 Nm (32 ft. lbs.).
^ Tighten the water pump plate to the front cover to 28 Nm (20 ft. lbs.).





9. Connect the by-pass hose to the water pump.
10. Install the engine lift bracket to the engine block. in Engine Mechanical - 6.5L.
11. Install the generator mounting bracket to the engine block.





12. Connect the radiator outlet hose to the water pump.





13. Install the water pump pulley to the water pump.
14. Install the water pump pulley mounting bolts.
^ Tighten the water pump pulley mounting bolts to 25 Nm (18 ft. lbs.).
15. Install the drive belt on the vehicle.
16. Install the fan clutch to the water pump pulley.

17. Install upper radiator shroud on the radiator.
18. Install the surge tank in the vehicle.
19. Connect the both battery negative cables to the batteries.
20. Refill the engine cooling system.
21. Using the following procedures, bleed the air from the engine cooling system.
21.1. Remove the cap from the surge tank.
21.2. Remove the bleed screw (slotted) from the top of the thermostat housing.
21.3. Pour coolant into the surge tank, and watch for coolant flowing from the bleed screw.
21.4. When a constant flow of coolant is reached, closed the bleed screw at the top of the thermostat housing.
21.5. Continue to fill the surge tank to the proper level.
21.6. Install the cap on the surge tank.





22. Install the air intake duct to the turbocharger.
23. Install the air cleaner assembly in the vehicle.
24. Inspect the system for coolant leaks.