Safety Glasses
Nitrile Gloves
Drain Pan
Ratchets
Sockets
Shop Towels
Water Pump
Fan Wrench Set
Coolant/Antifreeze
Step 1: Let Vehicle Cool and Disconnect Battery
Start by parking on a level surface and letting your vehicle cool. Then disconnect the negative battery cable.
Step 2: Slowly Remove Surge Tank Cap
Slowly rotate the surge tank fill cap counterclockwise. Stop rotating and allow the hissing to stop. After all hissing stops, continue turning counterclockwise to remove the cap.
Step 3: Position Drain Pan Under Vehicle
Put the drain pan under the vehicle to catch any fluids from the engine.
Step 4: Open Petcock and Drain Completely
Once the drain pan is in place, open the petcock and allow the system to drain completely. Once drained, close the radiator petcock.
Step 5: Remove Engine Cover
Take off the engine cover by loosening the intake manifold sight bolt shield and remove the cover from the cover retainer. Remove the cover retainer bolts and the retainer, if required.
Step 6: Remove Air Cleaner Outlet Duct
Loosen the air cleaner outlet duct clamps at the throttle body and mass airflow/intake air temperature sensor. Then remove the radiator inlet hose clip from the outlet duct. Finally, remove the air cleaner outlet duct.
Step 7: Detach Radiator Vent Inlet Hose
Detach the radiator vent inlet hose from the radiator hose clips. Loosen the inlet hose clamp and remove the inlet hose from the water pump.
Step 8: Remove Fan Shroud Retainers
If equipped, remove the throttle body heater hose retainer and the inlet radiator hose retainer from the fan shroud. Now you can remove the fan shroud retainers.
Step 9: Remove Upper Fan Shroud and Bolts
After removing the fan shroud retainers, remove the fan shroud bolts. Then, remove the upper fan shroud from the vehicle. You won’t be able to fully remove the lower fan shroud until the fan and clutch have been removed.
Step 10: Attach C-Clamp to Water Pump Pulley
Attach the c-clamp to the water pump pulley.
Step 11: Use Fan Clutch Wrench to Remove Fan Hub Nut
Attach a fan clutch wrench to the fan clutch. Remove the fan hub nut from the water pump by turning counterclockwise.
Step 12: Remove Fan
Remove the fan from the vehicle and lay it blade face down on a workbench.
Step 13: Remove Accessory Drive Belt
Remove the accessory drive belt by using a breaker bar with a hex-head socket on the drive belt tensioner bolt. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. Then you can remove the belt from the pulleys and tensioner.
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Do It Right: Slowly release the tension on the tensioner, then remove the breaker bar and socket. Clean and inspect the belt surfaces of all the pulleys. |
Step 14: Remove Outlet Hose from Water Pump
Back on the water pump itself, you can now loosen the attaching hose clamps and remove the outlet hose.
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Do It Right: Place a drain pan under the hoses you will be detaching and cover any belts with a waterproof plastic. |
Step 15: Remove Surge Tank Outlet Hose
After removing the radiator hose from the water pump, remove the surge tank outlet hose from the housing.
Step 16: Remove Heater Inlet Hose
After removing the previous two hoses, remove the heater inlet hose from the water pump.
Step 17: Remove Water Pump Outlet and Thermostat
Remove the two bolts that hold the water pump outlet and thermostat in place and then pull the thermostat from the water pump.
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Do It Right: The thermostat on your vehicle may not be directly attached to your water pump. |
Step 18: Remove Water Pump Bolts
Remove water pump bolts from the water pump.
Step 19: Remove Water Pump and Gaskets
After removing the water pump bolts, remove the water pump and gaskets completely. The old water pump gaskets can be discarded, as they will not be used.
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Do It Right: Make sure all gasket sealing surfaces are free of oil or any foreign material during assembly. Use gasket remover or a clean gasket-removing tool to ensure that the surfaces are free of any old material. |
Step 20: Install New Gaskets on Water Pump
Install the new gaskets to the water pump before installation.
Step 21: Install Water Pump
Place the new water pump in position after the new gaskets have been installed.
Step 22: Install Water Pump Bolts
Install new water pump bolts to secure the water pump in place. Tighten the bolts during the first pass to 11 foot pounds, and then 22 foot pounds for the final pass.
Step 23: Install Water Pump Outlet and Thermostat
Install the new water pump outlet which includes the thermostat. Make sure to use the new thermostat O-ring. Tighten the water pump outlet and thermostat to 11 foot pounds.
Step 24: Reinstall Hoses
Now you can reinstall the heater inlet hose, surge tank outlet hose, and outlet hose and tighten the hose clamps.
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Do It Right: If you need to change your radiator hose, this would be a great opportunity to do so. You can find out more about replacing the radiator hoses on your Vortec V8 Engine here. |
Step 25: Reinstall Accessory Drive Belt
Reinstall the drive belt by routing it around all of the pulleys except the idler pulley. Then use your breaker bar and socket to rotate the tensioner clockwise. Install the drive belt under the final idler pulley and slowly release tension on the belt tensioner. Remove your breaker bar and socket and inspect the belt for proper alignment.
Step 26: Reinstall Fan Blade
Install the fan blade, and using the fan clutch installer, tighten the fan clutch nut clockwise to 41 foot pounds.
Step 27: Reinstall Fan Shroud
Reinstall the fan shroud and bolts, and tighten the bolts to 80 inch pounds. Install the fan shroud retainers and, if equipped, install the inlet radiator hose and throttle body heater hose retainer to the fan shroud.
Step 28: Reinstall Radiator Inlet Hose
Install the inlet hose and hose clamp on the water pump.
Step 29: Reinstall Air Cleaner Outlet Duct
Install the air cleaner outlet duct. Install the radiator inlet hose clips to the outlet duct. Tighten the air cleaner outlet duct clamps at the throttle body and MAF/IAT sensor to 62 inch pounds.
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Do It Right: Be sure the arrow at the throttle body end of the duct is in alignment with the throttle body attaching stud. |
Step 30: Reinstall Engine Cover
Install the engine cover retainer by putting it in place and securing it with the retainer bolts, if required. Tighten the bolts to 44 inch pounds. Install the engine cover.
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Do It Right: Don’t let the cover contact the manifold absolute pressure sensor wire harness connector. |
Step 31: Refill Cooling System
Refill the cooling system, and reinstall the reservoir cap. Be sure to follow your vehicle manufacturer's specifications for coolant, type, ratio and fill procedure.
Step 32: Reconnect the Battery Cable
Reconnect your negative battery cable. Start your vehicle, and let it warm up to operating temperature with the heater on. If the heater is blowing warm air, turn the truck off and check the coolant level. Add coolant as needed.
Step 33: Remove Drain Pan and Close Hood
Before moving your vehicle, make sure to remove the drain pan from under your vehicle. Finally, close the hood.
The automotive repair work depicted in this series is performed under the direction of the manufacturer of the product featured. Prior to undertaking any of the demonstrated repairs on your vehicle, we suggest you consult with a certified mechanic or another professional who can adequately advise you of the proper repair or remedy required. O’Reilly Automotive Stores, Inc. and its affiliates (“O’Reilly”) disclaims any responsibility for injury or damage resulting from a viewer’s attempt to recreate the repairs shown in this series.