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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1355 (Engine Cooling System) >> Repair Instructions >> Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines) >> Installation Procedure

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.
IMPORTANT: All gaskets surfaces are to be free of oil or other foreign material during assembly.
  1. Install the water pump and NEW gaskets.
    NOTE: Refer to FASTENER NOTICE .
  2. Install the water pump bolts.

    Tighten 

    1. 2.1. Tighten the bolts a first pass to 15 N.m (11 lb ft).
    2. 2.2. Tighten the bolts a final pass to 30 N.m (22 lb ft).
    Fig 1: Install Water Pump, Gaskets & Bolts
    G02109217Courtesy of GENERAL MOTORS CORP.
  3. Install the heater inlet hose to the water pump.
  4. Position the heater inlet hose clamp at the water pump.
    Fig 2: Install Heater Inlet Hose
    G02109218Courtesy of GENERAL MOTORS CORP.
  5. Install the surge tank outlet hose to the water pump.
  6. Position the surge tank outlet hose clamp at the water pump.
    Fig 3: Install Surge Tank Outlet Hose
    G02109219Courtesy of GENERAL MOTORS CORP.
  7. Install the outlet hose to the water pump.
  8. Position the outlet hose clamp at the water pump.
  9. Install the accessory drive belt. Refer to DRIVE BELT REPLACEMENT - ACCESSORY .
  10. Install the fan blade. Refer to Fan Replacement .
    Fig 4: Install Outlet Hose
    G02109220Courtesy of GENERAL MOTORS CORP.
  11. Install the inlet hose to the water pump.
  12. Position the inlet hose clamp at the water pump.
    Fig 5: Install Inlet Hose
    G02109221Courtesy of GENERAL MOTORS CORP.
  13. Install the engine vent inlet hose to the radiator hose clips.
  14. If necessary, install the engine sight shield. Refer to ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, and 6.0L Engines) or  ENGINE SIGHT SHIELD REPLACEMENT (6.0L ENGINE W/RPOS Y91 and Z88)  .
    Fig 6: Install Engine Vent Inlet Hose
    G02109222Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud.
  15. Install the air cleaner outlet duct.
  16. Install the radiator inlet hose clip to the outlet duct.
  17. Tighten the air cleaner outlet duct clamps at the following locations:
    • Throttle body
    • MAF/IAT sensor
      1. Tighten 
      2. Tighten the clamps to 7 N.m (62 lb in).
  18. Fill the cooling system. Refer to Draining and Filling Cooling System .
    Fig 7: Install Air Cleaner Outlet Duct
    G02109223Courtesy of GENERAL MOTORS CORP.
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