DIY: Dodge 4.7L V8 Water Pump Replacement

Video tutorial on how to replace the water pump on a Dodge 4.7L V8, but it also does apply to other Chrysler models produced. Similar procedure can be used on the 1999 - 2009 Jeep Grand Cherokee, 2000 - 2011 Dodge Dakota, 2000 - 2009 Dodge Durango, 2002-2012 Dodge Ram 1500, 2006 - 2009 Jeep Commander, 2007 - 2009 Chrysler Aspen. This particular tutorial was done on a 2003 Dodge Dakota 4.7L V8 2wd.

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Tools/Supplies Needed:
-drain pan
-new coolant and distilled water
-socket set and ratchet
-vaseline
-torque wrench
-small adjustable wrench
-needle nose pliers
-wrenches
-hammer
-abrasive pad or emery paper
-clean rag
-new serpentine belt
-new mechanical fan clutch assembly

Procedure:
-first style by removing the washer fluid tank, disconnect the rubber hose and the two electrical connectors on the pump and level sensor
-the fluid will drain so have a drain pan handy or plug the pump
-now remove the two bolts on each side of the washer tank using a 10mm socket, 6" extension, and 3/8" drive ratchet
-remove hose by radiator cap for expansion tank
-remove two 10mm bolts on the top of the radiator which fasten it to the radiator support
-place a drain pan below the radiator and use a small adjustable wrench to loosen the drain plug
-the drain plug only rotates a quarter turn
-use needle nose pliers to pull out the drain plug
-use a larger adjustable wrench to loosen the clutch fan, leave the serpentine belt in place
-to remove the serpentine belt, use a 15mm wrench and rotate the bolt clockwise to relieve the tension
-place the drain pan under the water pump area
-check both the idler and tensioner pulleys to ensure they are in good working condition
-remove the idler pulley next to the water pump using a 15mm wrench
-use a 13mm to remove the water pump bolts
-when removing the water pump bolts, make note of all the locations as they are not the same
-sometimes the pump can be stuck in place, use the handle of a hammer to tap it free
-apply a small amount of vaseline to the new o-ring and push it into place
-use an abrasive pad or emery paper to clean the sealing surface, than wipe clean with a rag
-no need for silicone on the sealing surface
-when installing the new pump, tighten down evenly in a crisscross pattern
-to install a new mechanical clutch fan and remove the fan itself, use a 13mm to remove the bolts
-installation of all other parts in reverse of removal
-fill the system with coolant
-only use distilled water when mixing the coolant if need
-squeeze the lower rad hose to help push air from the system
-once filled, leave the radiator cap loose, start the vehicle and allow the engine to warm up

Torque Specifications:
Water pump - 43 ft. lbs.
Idler pulley - 40 ft. lbs.
Fan to mechanical clutch - 20 ft. lbs.

Symptoms of water pump failure:
-leaking gasket between the water pump housing and engine block
-worn seal around the shaft bearing which causes the coolant to leak out the bearing vent hole
-worn out bearing which would make a howling or grinding noise
-excessive "play" in the water pump shaft

Causes:
-regular usage which causes wear over time (routine maintenance)
-broken mechanical fan which causes the water pump shaft to be off balance
-worn mechanical clutch fan assembly which causes the water pump shaft to be off balance
-leaking water pump shaft seal which washes out the lubricant within the bearings
-worn/dried out gaskets/seals that cause a coolant leak

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