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Unread 02-06-2012, 01:59 PM   #1
PAXJ98
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1998 XJ Cherokee 
 
Join Date: Sep 2010
Location: Myerstown, PA
Posts: 122
Water Pump Replacement

Normally I'd take my good old time and research this well, but unfortunately I don't have much in the way of time on my side right now - otherwise I'm sure I would have found my answers with a thorough search. However...

I've got a '98 XJ, 4.0, and I need to replace my water pump (shop back home investigated it for me since I didn't know what the sound was, but I didn't have the time to have them take care of it because I had to get back to school). Does anyone know of a write-up on this for my setup, or can someone give me some general instructions? I need to have the XJ up and running in the next three days, so any and all help is appreciated!

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Unread 02-06-2012, 02:20 PM   #2
mortalenema
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1999 XJ Cherokee 
 
Join Date: Dec 2006
Location: Minneapolis
Posts: 1,353
WATER PUMP
REMOVAL-4.0L ENGINE (LHD/RHD)

(1) Disconnect battery negative cable.
(2) Drain the cooling system.
(3) Disconnect electric cooling fan connector.
(4) Remove electric cooling fan/shroud assembly (if
equipped).
(5) Remove viscous fan shroud bolts (2).
(6) Loosen (but do not remove at this time) the
four water pump pulley-to-water pump hub mounting
bolts and the four viscous fan to idler pulley
nuts.
NOTE: The accessory drive belt must be removed
prior to removing the fan (if installed at pump) or
fan pulley.
(7) Remove accessory drive belt
(8) Remove the four viscous fan to idler pulley
nuts and remove the fan and shroud together.
CAUTION: After removing fan blade/viscous fan
drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into
its bearing assembly and contaminate lubricant.
(9) Remove the four water pump pulley bolts and
remove the pulley.
(10) Remove power steering pump and bracket.
(11) Remove lower radiator hose from water pump.
Remove heater hose from water pump fitting.
(12) Remove the four pump mounting bolts
and remove pump from vehicle. Discard old gasket.
Note that one of the four bolts is longer than the
other bolts.
(13) If pump is to be replaced, the heater hose fitting
must be removed. Note position of fitting before
removal.

WATER PUMP
INSTALLATION-4.0L ENGINE (LHD/RHD)

(1) If pump is being replaced, install the heater
hose fitting to the pump. Use a sealant on the fitting
such as Mopart Thread Sealant With Teflon. Refer to
the directions on the package.
(2) Clean the gasket mating surfaces. If the original
pump is used, remove any deposits or other foreign
material. Inspect the cylinder block and water
pump mating surfaces for erosion or damage from
cavitation.
(3) Install the gasket and water pump. The silicone
bead on the gasket should be facing the water
pump. Also, the gasket is installed dry. Tighten
mounting bolts to 23 Nm (17 ft. lbs.) torque. Rotate
the shaft by hand to be sure it turns freely.
(4) Connect the radiator and heater hoses to the
water pump.
(5) Position water pump pulley to water pump
hub.
(6) Install four pump pulley bolts. Tighten bolts (or
nuts) to 27 Nm (20 ft. lbs.) torque.
(7) Install power steering pump.
(8) Install the viscous fan and shroud together.
Install the four fan to idler pulley nuts and tighten
to 27 Nm (20 ft. lbs.).
CAUTION: When installing the accessory drive belt,
the belt MUST be routed correctly. If not, the engine
may overheat due to the water pump rotating in the
wrong direction.
You may also refer to the Belt Routing Label in
the vehicle engine compartment.
(9) Install and tighten viscous fan shroud bolts to
4 Nm (31 in. lbs.).
(10) Install and tension the accessory drive belt.
(11) Install the electric cooling fan/shroud assy.
(12) Install and tighten electric fan shroud bolts to
4 Nm (31 in. lbs.). Connect fan connector.
(13) Fill cooling system with coolant and check for
leaks. .
(14) Connect battery negative cable.
(15) Start and warm the engine. Check for leaks.

THERMOSTAT
REMOVAL

WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 6). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVICING
CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(2) Remove radiator upper hose and heater hose at
thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat.
Discard old gasket.
(5) Clean the gasket mating surfaces.
INSTALLATION
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cylinder
head.
(b) Position thermostat into this groove with
arrow and air bleed hole on outer flange pointing
up.
(2) Install replacement gasket and thermostat
housing.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.
(3) Tighten the housing bolts to 20 Nm (15 ft. lbs.)
torque.
(4) Install hoses to thermostat housing.
(5) Install electrical connector to coolant temperature
sensor.
(6) Be sure that the radiator draincock is tightly
closed. Fill the cooling system to the correct level
with the required coolant mixture.
(7) Start and warm the engine. Check for leaks.
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Unread 02-07-2012, 10:52 PM   #3
joe108
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2003 TJ Wrangler 
 
Join Date: Aug 2011
Location: valley center, ca
Posts: 812
Will be completing a complete cooling system overhaul in the morning on mine, the pump is fairly easy to get too, just take your time, clean up the gasket surfaces real good. The hardest part is usually removing the stuff around it like the PS pump and hoses, good instructions ^
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Unread 02-08-2012, 06:44 PM   #4
PAXJ98
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1998 XJ Cherokee 
 
Join Date: Sep 2010
Location: Myerstown, PA
Posts: 122
Thanks again for the instructions - XJ's up and running again, purrs like a kitten! Surprised that water pump didn't go... thing was as loose as they come. Good news is the belt and thermostat were still in nice condition
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Unread 02-08-2012, 07:56 PM   #5
tiny43
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Join Date: Apr 2011
Location: Harrisburg, AR
Posts: 38
pita

I just replaced mine via Haynes manual and it was a pita. I ended up removing the fan shroud the electricfan, airbox, the power steering pump and bracket and the idler pulley to get the the water pump off. There are two bolts that hold the power steering pump brace to the water pump. A total of 8 bolts and one nut to remove the power steering pump and bracket. Absolutely do not forget to loosen the waterpump pulley bolts first after removing the fan and shroud. I forgot and fortunately I was able to get two out and put in two longer bolts to hold it stable with a large screwdriver and get the other two loose. It was the most drawn out process of putting on a water pump I have ever experienced.
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Unread 05-26-2013, 06:00 PM   #6
bikerjim
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1989 XJ Cherokee 
 
Join Date: Oct 2012
Location: Chocowinity, NC
Posts: 5
I just replaced the water pump on my '89 Pioneer 4.0L I (320,xxx miles). I also had to remove the electric aux cooling fan, pwr steering pump and pump brace. Luckily I did loosen the 4 water pump bolts prior to removing the serpentine belt. I replaced the belt also since it had quite a few cracks on the ribbed side. I read several write-ups here as well as referencing Haynes. I don't remember the last time I replaced a water pump, if ever, but this seemed to take more time than I expected. AND I really appreciate the write-ups here and the wealth of info available to backyard wrench monkeys like myself!
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Unread 05-26-2013, 10:12 PM   #7
MikeT3
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1996 XJ Cherokee 
 
Join Date: Mar 2013
Location: Crescent City, CA
Posts: 32
I just replaced my water pump and it took about 3 hours. The key as bikerjim said "loosen the 4 water pump bolts prior to removing the serpentine belt". The only other thing is getting all the air out of the system the dam top hose sits higher than the radiator fill which then create a large air pocket.
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Unread 05-27-2013, 03:05 PM   #8
blackfire
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1998 XJ Cherokee 
 
Join Date: Oct 2009
Location: st.pete
Posts: 128
I did the water pump the other night and it took me about an hour.
I didn't remove the shroud, mechanical fan, ps pump, or any of that other stuff. Just the e-fan and serpentine belt. It's a little tight, but definetly doable. I think taking all that other stuff off is a waste of time.
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