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Unread 10-20-2010, 12:09 AM   #1
Baja
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1997 ZJ 
 
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Location: Tijuana
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Jeep 4.0 water pump writeup

Hi Guys,

I recently changed the Water pump in my 97 ZJ, so I figured it was a great opportunity to do

my first writeup, so here goes...

1.- First you will need to drain all the coolant from the system, the radiator drain**** is at the bottom on the passenger side, please dispose of coolant responsibly.

2.- Loosen (but do NOT remove) the nuts holding the fan to the water pump, and remove the serpentine belt (the belt tensioner is at the power steering pump).

3.- As you can see here there is no space to remove the pump, so the fan & fan shroud need to come off.


4.- Remove the 2 nuts holding the fan shroud in place (shown opposite my belly ), and the nuts holding the Fan in place (the ones you loosened in step 2), this step was a PITA in my case.


5.- Here you can see how much more space there is after step 4.


6.- You will notice the Power steering pump is attached to a bracket, that is attached to the water pump (shown in picture below), so remove the PS pump (do not disconnect any PS hoses), and put it to the side, and remove the PS bracket.


7.- Here is the pump with bracket and PS pump removed.


8.- Remove the lower radiator hose, and the heater hose connected to a metal tube that goes to the water pump.

9.- Remove the bolts holding the water pump in place (one of the bolts is larger than the rest, remember where it goes), after this I TRIED to remove the pump, but noticed I could not remove it due to clearance issues with the metal tube between pulley and thermostat housing (see pic).


10.- So I decided to remove the thermostat housing and replace the t-stat while I was there,here is a pic of the t-stat with the housing removed.


11.- Clean all mating surfaces real good, for the water pump & thermo housing.


12.- You need to transfer the metal tube and the mounting studs for the fan to the new pump (note the position of the metal tube),I removed the studs with vise grips fairly easily. Here is a side by side old and new pumps.


13.- I used some RTV gasket sealant for the pump & thermostat housing (some people say you shouldnt do it, so its your choice).

14.- Installation is the reverse of removal, first the water pump.


15.- Then the housing (old one was in bad shape so I got a new one), and everything else !



Tips:
- Carefull when removing the connector for the coolant temp sensor, it is brittle and brakes easily (dont ask how I know).
- Fill with 50/50 water coolant mix.
- Check the coolant for a few days after to make sure you dont have any leaks and since air will be purged from the system, you may need to add more coolant.
- Install time was about 4 Hrs including lunch break and going to the store for new thermostat & housing.

Thats it, hope it helps somebody out !!!

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Unread 10-20-2010, 05:58 AM   #2
gothchick
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Very nice write up.
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Unread 01-05-2011, 02:55 PM   #3
igrok
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Dude, torque values? and after you install the pump, is there a way to check it for leaks or do you put it all back together and cross your fingers???
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Unread 01-06-2011, 10:58 AM   #4
Baja
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Sure... the water pump bolts need to be torqued at 22 ft/lbs.

As far as checking for leaks, I just crossed my fingers and hoped I wouldnt have to take everything apart again, the FSM says to install the gasket dry, but I used some black RTV as added insurance.

Let me know if you need any more info.
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Unread 01-06-2011, 08:23 PM   #5
igrok
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thanks! I finished my pump install today; on a 2000 4.0 I6, the torque value is 17 ft/lbs on the pump bolts, 23 ft/lbs on the fan/clutch bolts, and 22 ft/lbs on the pulley bolts.

I put the serpentine belt back on, new upper and lower rad hoses, filled up the radiator, and cranked the engine to let it warm up. I saw there was no leaks and waited for the hot water to start flowing in the top radiator hose (check be feeling the hose). Once I was happy the thermostat opened up and water was flowing where it should and NOT where it shouldn't, I let it cool down, put the fan and fan shroud on and called it a day.
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Unread 08-22-2012, 05:07 PM   #6
MarsZJ
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no matter what i do i cant find the last bolt holding the powersteering pump on
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Unread 08-22-2012, 07:47 PM   #7
KoreaZJ
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Quote:
Originally Posted by MarsZJ View Post
no matter what i do i cant find the last bolt holding the powersteering pump on
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Unread 11-13-2013, 09:41 AM   #8
Jayt96ZJ
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Thanks, Baja

Baja - Great write up. I'm a newbie and have a dripping water pump on my 1996 ZJ 4.0. Your instructions have given me the extra confidence to tackle this project soon.
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Unread 11-13-2013, 11:23 AM   #9
coralman
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Baja - Great write up. I'm a newbie and have a dripping water pump on my 1996 ZJ 4.0. Your instructions have given me the extra confidence to tackle this project soon.[/QUOTE]

He might not see you ...posted in 2010. I don't pay attention to the dates always either
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Unread 11-13-2013, 11:41 AM   #10
Jayt96ZJ
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Good catch, Coralman. I was SO excited about the write up, I forgot to look at the post date.
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Unread 09-15-2014, 05:41 PM   #11
paulannen
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About to start mine.... Wish me luck!
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Unread 09-15-2014, 05:56 PM   #12
mig1289
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Originally Posted by paulannen View Post
About to start mine.... Wish me luck!
Its not a bad job just take you're time. Might as will replace the radiator while you have the coolant drained too
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Unread 09-15-2014, 10:10 PM   #13
paulannen
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Aaaand done! Not bad time (3 hours) for a first time, after dark with a flashlight.... I already had a spair pump so no need to run to the parts store.. And no budget for a new rad.. Let's just hope there's no leaks overnight....
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Unread 09-15-2014, 11:53 PM   #14
AVR2
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FWIW, you don't need to remove the power steering pump. Just loosen it, and remove the one mounting bolt that goes through holes in both the steering and water pumps. Then you can slide the water pump out to the left.
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Unread 09-16-2014, 12:00 AM   #15
AmishFury
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i was about to say that... it is possible to remove the water pump without removing the PS pump bracket... the water pump itself comes out a little easier if you do but the whole job is simplified a bit if you don't
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4.0 , thermostat , water pump

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