Tips from an amateur mechanic and first time Jeep owner.
I had my water pump go on me Saturday afternoon (coincidentally, on the way to a Jeep event, but thankfully, not on the trail). I've done water pumps in other cars before, so fortunately, I didn't go into this blind. For step by step instructions, I more or less followed
from Youtuber ChrisFix. But even so, here are my observations on the process.
Torque Settings:
Thermostat housing bolts: 2004 2.4L - 28 N-m / 250 in lbs
1997-2002 2.5L - 18 N-m / 13 ft lbs
1997-2006 4.0L - 18 N-m / 13 ft lbs
1997-2006 any others - 20 N-m / 15 ft lbs
Water pump bolts: 2004 4.0L - 23 N-m / 200 in lbs
2004 2.4L - 12 N-m / 105 in lbs
1997-2002 2.5L - 31 N-m / 270 in lbs
1997-2006 4.0L - 31 N-m / 270 in lbs
any other 2.5L & 4.0L - 30 N-m / 22 ft lbs
I had my water pump go on me Saturday afternoon (coincidentally, on the way to a Jeep event, but thankfully, not on the trail). I've done water pumps in other cars before, so fortunately, I didn't go into this blind. For step by step instructions, I more or less followed
- Hydrate
- Fan & Fan Clutch Removal: remove serpentine belt first, remove upper radiator hose, use an 18" pipe wrench on the fan bolt, and a strap wrench on the water pump pulley, strike pipe wrench with hammer (regular carpenter's hammer, not BFH) to knock loose, have patience & be persistent, don't try to muscle strap wrench and pipe wrench together unless the strap wrench is heavy duty, or else you may pull out the rubber strap. Wait until nut is loose before removing fan shroud, undo fan nut last and remove as a group. Expect to lose at least some skin during the process. Celebrate all the new space you have to work in, it'll be your last celebration for a short while.
- Hydrate
- Pliers, Channel Locks, Vice Grips Or Witchcraft: When it comes to hose clamps, especially the larger diameter ones, use the right tool for the right job; the wrong tool takes entirely too long
- Hydrate
- Make A Hole: Don't forget to remove the top idler pulley, in order to free up the metal pipe on the water pump
- Hydrate
- Leverage: Be sure to remove hoses while parts are still securely fastened to the engine; you'll get much better leverage on them, and the same goes for putting them back on.
- Did I Mention Hydrate? It's summer, and I'm in Florida.
- Appreciate The Little Things: When it comes time to remove the water pump and thermostat housing (you are replacing the stat also, aren't you? You really should), enjoy the relative ease in which most of the bolts come off. You will never get this opportunity again.
- Working In The Rain Does Not Count As Hydrating: Though as long as the thunder stays on its side of the playground, it can be refreshing (once again, Florida)
- Gasket Mating Surfaces: It doesn't matter how long every other task takes, when you're ready to clean the gasket residue off the mating surfaces, TAKE YOUR BLOODY TIME!!! Everything else can look like a pathetic train wreck; in contrast, this needs to be perfect. Not following this rule means you'll be doing most of these steps again pretty soon.
- Workspace Maintenance: Keeping the kiddie pool between the car and the front door of the house can make an effective detour between tasks.
- Sealants: Any bolts or other fixtures that act as a water-tight pressure seal will need teflon thread sealant; you can either use the liquid stuff, but I've found that teflon plumbing tape works as well, and makes less of a mess.
- Time Management: Don't look at your watch; far more time has passed than you had originally planned for, and you really don't want to know specific details on how much.
- Torque Settings: learn them, love them, obey them, or else you do something random like, oh, I don't know, snap the thermostat housing in half and have to fork out $12 at the auto parts store for an emergency replacement (hypothetically, of course). See below for details.
- While You're At It: Wouldn't be a bad time to change your serpentine belt, either.
- Wrapping Up: By this time, you should be thinking less about a shower and more about somebody just hosing you down in the yard.
Torque Settings:
Thermostat housing bolts: 2004 2.4L - 28 N-m / 250 in lbs
1997-2002 2.5L - 18 N-m / 13 ft lbs
1997-2006 4.0L - 18 N-m / 13 ft lbs
1997-2006 any others - 20 N-m / 15 ft lbs
Water pump bolts: 2004 4.0L - 23 N-m / 200 in lbs
2004 2.4L - 12 N-m / 105 in lbs
1997-2002 2.5L - 31 N-m / 270 in lbs
1997-2006 4.0L - 31 N-m / 270 in lbs
any other 2.5L & 4.0L - 30 N-m / 22 ft lbs