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Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If reusing the old fasteners, apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts.
  2. Install NEW water pump gaskets and the water pump.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the water pump bolts.

    Tighten 

    Tighten the bolts to 45 N.m (33 lb ft).

    Fig 1: Install Water Pump, Gaskets & Bolts
    G02109202Courtesy of GENERAL MOTORS CORP.
  4. Using J 41240,  hold the water pump pulley, install the water pump pulley bolts.

    Tighten 

    Tighten the bolts to 25 N.m (18 lb ft).

    Fig 2: Install Water Pump Pulley Bolts Using J 41240
    G02109203Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: After assembly, the hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose.
  5. Install the water pump inlet hose.
  6. Position the water pump inlet hose clamps.
    Fig 3: Install Water Pump Inlet Hose
    G02109204Courtesy of GENERAL MOTORS CORP.
  7. Install the radiator outlet hose to the water pump.
  8. Install the radiator outlet hose to the surge tank.
  9. Position the radiator outlet hose clamps at the surge tank and water pump.
  10. Install the drive belt. Refer to DRIVE BELT ROUTING .
  11. Install the cooling fan. Refer to Fan Clutch Replacement .
    Fig 4: Install Radiator Outlet Hose
    G02109205Courtesy of GENERAL MOTORS CORP.
  12. Align the hinge clip with the lip on the throttle body.

    In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.

    Fig 5: Install Air Cleaner Outlet Duct
    G02109206Courtesy of GENERAL MOTORS CORP.
  13. Install the air cleaner adapter nut.
    Fig 6: Install Air Cleaner Adapter Nut
    G02109207Courtesy of GENERAL MOTORS CORP.
  14. Install the PCV hose.
    Fig 7: Install PCV Hose
    G02109208Courtesy of GENERAL MOTORS CORP.
  15. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
  16. Fill the cooling system. Refer to Draining and Filling Cooling System .
  17. Inspect the cooling system for leaks.
    Fig 8: Install Air Cleaner Outlet Duct Clamp
    G02109209Courtesy of GENERAL MOTORS CORP.
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