LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (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 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 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 in Cautions and Notices.
  2. Install the water pump bolts.

    Tighten: 

    1. Tighten the bolts a first pass to 15 N.m (11 lb ft).
    2. Tighten the bolts a final pass to 30 N.m (22 lb ft).

    3. Fig 1: View Of Water Pump, Gaskets & Bolts
    GM260121Courtesy 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.
    5. Fig 2: View Of Heater Inlet Hose At Water Pump
    GM660665Courtesy 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.
    7. Fig 3: View Of Surge Tank Outlet Hose To Water Pump
    GM659180Courtesy of GENERAL MOTORS CORP.
  7. Install the outlet hose to the water pump.
  8. Position the outlet hose clamp at the water pump.
    9. Fig 4: View Of Water Pump Outlet Hose
    GM846668Courtesy of GENERAL MOTORS CORP.
  9. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) or Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  10. Install the fan blade. Refer to Fan Replacement .
  11. Install the inlet hose to the water pump.
  12. Position the inlet hose clamp at the water pump.
    13. Fig 5: View Of Radiator Inlet Hose
    GM846666Courtesy of GENERAL MOTORS CORP.
  13. Install the engine vent inlet hose to the radiator hose clips.
    14. Fig 6: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  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) in Engine Mechanical - 4.8L, 5.3L, and 6.0 L.
    15. 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. Fig 7: View Of Air Cleaner Outlet Duct
    GM832066Courtesy of GENERAL MOTORS CORP.
  17. Tighten the air cleaner outlet duct clamps at the following locations:
    • Throttle body
    • MAF/IAT sensor

      Tighten:  Tighten the clamps to 7 N.m (62 lb in).

  18. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)  or Draining and Filling Cooling System (without HP2) .
scientia non olet · About LEMON Manuals