Water Pump Replacement, Thermostat Replacement How-To

Water Pump Replacement, Thermostat Replacement How-To

Postby chemist [OP] » March 29th 2009, 4:28am

Your water pump may eventually fail. I hope it never does, but my friend's did on his 96 Astro van. We changed it last weekend along with some other stuff. It was my first time for this on an Astro, but perhaps someone else can benefit from that experience. I won't mislead you, I consider this job kind of a pain. If you're going to do it, replace your hoses and thermostat so you hopefully don't have to mess with the cooling system for a while. It is certainly do-able by many of us, and who doesn't want to have this job done for under $100 when it is needed.

I can't show you a picture of your water pump yet, because we'll need to expose it first.

You'll need your basic metric wrenches, metric sockets and socket extensions. You'll also need a GM fan clutch removal tool. The exact GM tool is J46406, I think, but don't run out and spend $150 on that. Such things are available at places like Advance Auto Parts—they would have rented us a tool kit for this, but they were out so we had to use a Ford Fan Clutch removal wrench set, exactly like this one at the top of the following web site—we found it for $22 so don't pay that price.... http://www.mytoolstore.com/kd/kdengi06.html You may be able to get by with a really large strap wrench and a huge cresent wrench, but we couldn't get that to work.

Before you start this, disconnect the battery!

Water Pump

1. Make sure the engine and coolant are cool. Place a large basin under the van and open the radiator stopcock found at the bottom of the radiator, facing the interior of the van on the passenger side—make sure that the coolant goes into the basin. You may wish to use pliers on the spring for the lower radiator hose and remove it at this point too at this point.

2. Now remove your air intake as per this procedure: http://www.astrosafari.com/viewtopic.php?f=9&t=1142

3. Next remove the upper fan housing as per this procedure: http://www.astrosafari.com/viewtopic.php?f=9&t=1143
3a: Remove the serpentene belt as shown here: http://www.astrosafari.com/viewtopic.php?f=9&t=1144

4. The fan clutch removal tool that I used consisted of a large really thin wrench and an even bigger, but just as thin, crows foot wrench. Because of the tight space we simply could not get good photos of the tool in use. To use the tool, first put something with a half inch drive on the crows foot wrench and slip the crows foot wrench over the four small bolts on the fan/water pump pulley. You may need to align the bolts so that they are all flat side facing the sides of the crows foot wrench—sorry for not writing down bolt sizes, I think they're either 10 or 13 mm bolts. Use the box end of a wrench for that task if you need to do it. Now slip the open end wrench on the large nut between the fan and the pulley, hold the crows foot wrench in place and turn the nut between the fan and pulley counterclockwise (from the drivers side to the passenger side). This may be require considerable effort... Here's a photo of the nut I was talking about and the four bolts on the pulley:
Image

5. Now remove the pulley from the water pump. Because the pulley spins, I found it easiest to zip them off with a 3/8” drive impact wrench. If that's not an option for you, try to hold it in place with a large strap wrench and remove the bolts (10mm socket if I remember correctly, could have been 12):
Image

Okay, there's your water pump.
Image

6. If you are changing hoses—and you should be—you'll want to pull out the lower fan housing at this point. It has plastic tabs holding it at the bottom, so try not to break them as you unclip them. You'll also need to remove the lower radiator hose at the bottom of the pump—his wouldn't separate from the water pump so we just cut it with a pair of pruning sheers—the kind you cut branches with. The hose has a spring in it so have wire cutters handy if you do that... Remember to get a basin under the hose before you remove it.
Image

7. Next pull the line off the top of the water pump as shown.
Image

8. It's probably best if you remove the center top pulley, shown below. To remove it, simply remove the bolt in the center.
Image

9. This will reveal another hose on the top of the water pump. Remove that hose from the water pump.
Image

10. Now you're ready to pull of the old water pump. It's held in by four bolts on the front (15mm bolt heads if I remember right). Remove those bolts, but have a hand on the water pump to catch it for the last one.
Image

11. Sorry, no photos of this, but you'll find old gasket left behind where the water pump bolted on. Scrape those off as best you can. Sorry, no photos here. Apply rtv to the new water pump, place the new gaskets on the water pump and apply rtv to other sides of the gaskets as well.

12. Now, bolt the new water pump back on.
Image

13. Reinstall everything you removed. Sorry, no more photos there.

Thermostat

1. To replace the thermostat, you'll need to first pull the upper radiator hose from the thermostat housing. Here is the upper radiator hose, follow it back toward the motor.
Image
It connects to the thermostat housing. Here is the housing with the thermostat shown inside (hose pulled)
Image

Now pull the wiring harnesses off of the sensors that are in your way.
Image

Next unbolt the thermostat housing cover and pull it off. Note: On the back side of it (facing the engine, you'll actually find two nuts. One attaches a ground lead to the back of the stud on the back of the thermostat. I mention it so you don't break the thing trying to pull it off.
Image

Pull out the old thermostat.
Image

Pop the new thermostat and bolt the cover back on. Remember to reattach the sensor wiring harnesses you just pulled and the pulley. Sorry, no more pics.

Torque Settings
Thermostat cover nuts: 18 ft/lb
Water Pump Bolts: 33 ft/lb
Water Pump/Fan Pulley Bolts: 18 ft/lb
Fan clutch nut: 41 ft/lb – I have no idea how you'd set that... :banghead:

Notes:
* You may wish to double check my torque specifications before using them for your vehicle
* Engine coolant is poisonous, generally sweet tasting, and harmful to the environment. Be careful to collect all of it and properly dispose of or recycle it. This goes doubly if you have pets
* I am only providing this procedure to tell you how I did this. In no way am I telling anyone to do this, especially if they're not comfortable with this repair. Also note, I'm a chemist not a lisenced mechanic, so as with all things, consider the source.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby Matrixx » March 29th 2009, 10:03am

That's a great write up chemist, I'm sure others will really benefit from it, Thanks.:)
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby sothrowd08 » April 4th 2009, 10:44pm

thanks for providing this AFTER I replace my water pump gaskets. I actually left the fan and clutch on, so it was a real biotch.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby fede » April 5th 2009, 3:35am

Wow great write up, thanks for the information!!
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby cybrvanr » April 15th 2009, 3:28am

I noticed it looked a little grimy around the front crankshaft seal...this is a perfect time to replace that while you have it all apart...That's what I did on my 88 van
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby ghostrider1061 » June 29th 2009, 7:06pm

thanks for the write-up. lotta good info. sounds like a 6 pack job to me also a major pita. but if low on cash it pays to be a do-it-yourselfer, many of us can benifit from info and write-ups like yours. :goodpost: :ty: :coolphotos:
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby Gus_Mahn » January 9th 2010, 1:43am

Good write up!
Some guys will loosen the fan clutch using an air hammer with a flattened chisel or round head bit. They hit on the edge of a flat to loosen or tighten the nut. I didn't have either tool to do my van, so I took the back off the old pump (off the van) and jammed a screw driver into the impeller while turning the clutch nut with a big adjustable wrench. I put it back together with the adjustable wrench and a strap wrench.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby KADMANDAK » June 9th 2010, 7:00pm

This is a great post. (I wish I would have found/read it before I changed the water pump on my 1998 Astro AWD).

As far as the fan clutch tool, I visited AutoZone, which only had the Ford tool kit to rent out. I did not come home with the tool as there was nothing in the kit that could be used to hold the water pump sheave from turning when trying to loosen the big nut on the water pump shaft.

I had success (holding the pulley) by using a short length of swing-set chain through one of the four pulley mounting bolts. As a precaution (and not to mess up the threads of the original bolt), I did buy a slightly longer Metric bolt to secure the chain. I took the other end of the chain and secured it over steering links directly below with a “quick-link”.

The steering linkage was of heavy diameter to take the load as I worked the big nut loose with a large Crescent wrench. The (right-hand thread) nut was on tight, but not Godzilla tight. I recall the GM manual saying the tightening torque for the big nut to be about 48-Ft-Lbs.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby awesomeastro » September 18th 2011, 5:07am

I found this and made a similar tool for fan removal. It worked perfect and was free!!! I actually did it a bit different. I took one of the 4 bolts out and drilled the hole in the bar the same size and threaded it back on so it held the tool against the black bit and made sure it wouldn't slip off and smack my hands on something.
no need to buy proper tool
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby awesomeastro » September 18th 2011, 5:13am

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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby redfury » September 20th 2011, 6:36am

Two ways to get that big nut loose, a strap wrench and a 36mm wrench, or the other cheaper way if you need to buy a tool ( that wrench was 40 bucks! ) ...went and bought me the biggest crescent wrench I could find within reason and a 2 1/2lb mini sledge. Put the crescent wrench on the bolt and smack it with the hammer to loosen. Might take a few blows ( keep the belt on for now ) but it'll come off.

As far as the water pump itself, you can leave the pulley on it until you get it off as it's not really in the way being that the 4 bolts that hold it on ( the water pump ) are on the left and right of the pump.

What gave me fits was getting the pump back on without crushing one of the gaskets. I took 3" bolts of the same thread pitch, cut the heads off, ground a slot in the end for a screwdriver and put them in to guide the water pump up to the block. For me, it's a necessity since I have a hard time handling a cast iron water pump with one hand while trying to thread the nuts ( carpal tunnel sucks ), so the guides did the trick for me ( after 2 sets of gaskets blowing out shortly after warming the motor up to temp ) There's room to do it, I wish GM had just studded bolts in at least 2 of the 4 bolt holes in the first place.

Oh, and make sure you have perfectly clean gasket mating surfaces or you are asking for a leak. If you use water pump gasket sealant, don't slather it on, just a nice thin film is all you are going to need.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby tedanderson » September 22nd 2011, 12:42am

X2 on the thin layer of RTV sealant. Less is definitely more.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby ed t » April 29th 2012, 6:56pm

thanks for the write up, all i'm attempting is the thermostat, but i'm glad you pointed out the double nuts for the ground wire. i did have the water pump replaced at the dealer (yes, was a bit pricey, but it wasn't something i was willing to attempt.) now the thermostat is shot... i figured i could give that a try since is is sorta visible just looking at the engine. took off the air cleaner, and top radiator hose, disconnected some sensors and started wrenching. got the first nut off from the grounding wire OK, when i tried the bolt on the back of the thermostat housing i rounded off the nut... used a craftsman 6 point deep socket and it just spun around... i tried a 'gator grip' socket with the pins inside that is supposed to grab onto anything, well the stud is too tall for it to get a grip. now i'm worried about the other bolt in the front. my deep socket is too tall to fit under the cruise control bracket and yanking on it with an open end wrench isn't working yet either... i have them both soaking in liquid wrench, but i don't think rust is an issue.

anybody have any suggestions?

thanks for listening
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby Jasen » April 29th 2012, 7:35pm

Tapping on it can help sometimes, also heat or heating while tapping. Once you get it cracked loose, if it's still stiff to get out, work it back and forth progressing a little farther each time.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby ed t » April 29th 2012, 8:28pm

thanks for the tip, i did manage to get them both out. it turns out that the nut for the electrical ground was 14mm but the housing nuts are 13mm. managed to move the cruise control bracket just enough to get a socket on. both studs came out with the nuts still on them. i'm thinking i'll replace those too. these forums have helped a bunch over the years.
my wife thanks you all as well since it's her van :)
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby Ericglo » June 24th 2012, 9:44pm

Here is a pic of the Autozone rental tool. I struggled with this till I finally figured out what was going on. Loosen the four bolts to line up on the tool. Just remember to tighten them when your done or you will get a noise that you won't like. :D
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby Ericglo » June 24th 2012, 9:45pm

Oh and the tool to rent is the one with two in the box not the one with five tools. I rented both, because they didn't know which one fit.
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby AWDASTROVAN1999 » June 24th 2012, 10:02pm

The water pump is the one part Ive never changed on my van,,,, I remember that whenever I take her on a long trip... I think having a cracked radiator has kept my system clean as i add fluid every 3 days when I use her ..


Nice write up

Thanks
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby Swong » September 1st 2012, 5:17am

Cover the radiator with a piece of cardboard soon as u take the fan off ...
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Re: Water Pump Replacement, Thermostat Replacement How-To

Postby TroySmith80 » April 23rd 2013, 4:36am

Wow, i'm stuck at step 1, lol!

Is the drain petcock supposed to be a 1/4 turn unit like the petcock on a gas tank or garden hose? Or do you have to unscrew it a lot? I'm afraid that thing might be broken because i had to get pliers on it to turn it, and nothing happened at 1/4 turn, or a full turn. After several turns (counter-clockwise, unscrewing) i started to get coolant but i'm pretty sure it was coming out around the petcock itself, not from the drain tube.

That petcock is hard to reach! I guess i'd have to pull the whole radiator to replace it. I'm not excited about this whole thing. I just want to sell the van and somebody test drove it and it started leaking coolant at the pump! Now it's leaking pretty badly so i'm going to have to fix it before anyone will buy it. *grumble*
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