How to Replace a Water Pump on a 1996 Chevy Van

The water pump on your 1996 Chevy G-series van is responsible for keeping the engine coolant circulating throughout the cooling system, which prevents the engine from overheating. If the water pump fails or begins to leak, you need to replace it. Experienced home mechanics should be able to replace the water pump in a couple of hours.

Instructions

1

Locate the Chevy van's radiator drain plug. Place the drain pan with the umbrella (a drain pan extender) under the drain plug. Make sure the umbrella is placed so it will catch coolant from the lower radiator hose. Open the drain plug by turning it counterclockwise by hand and allow the cooling system to drain. Remove the radiator cap by pressing down and turning counterclockwise, then lifting the cap off.

2

Remove the two to four bolts that secure the fan shroud to the radiator by turning them counterclockwise with a wrench or socket and ratchet.

3

Remove the four bolts that secure the fan clutch and pulley to the water pump snout by turning them counterclockwise with a inch wrench or socket and ratchet. Remove the fan and shroud.

4

Insert the square drive of the ratchet into the square opening in the tensioner pulley assembly and rotate it counterclockwise to release the tension on the belt. Remove the belt and water pump pulley.

5

Remove any power steering pump or AC compressor mounting bolts that block access to the water pump by turning them counterclockwise with a socket and ratchet.

6

Loosen the clamp on the lower radiator hose by turning it counterclockwise. Slide the clamp to the middle of the hose. Grasp the hose at the point of connection and twist while pulling. You might need to insert the screwdriver between the hose and pump nipple to break the seal.

7

Remove the five to seven bolts that secure the water pump to the block by turning them counterclockwise. Grasp the water pump snout and pull up and out, being careful to not hit the radiator. Scrape the remnants of the old gasket from the block.

8

Apply a thin bead of RTV blue sealant to the gasket mating surfaces of both the block and the water pump. Apply the gasket to the water pump and hold the water pump in place. Insert the bolts through the mounting holes and thread them in by turning them clockwise by hand. Tighten these bolts to 30 foot-pounds with the ratchet.

9

Reinstall any bolts you removed to gain access to the water pump bolts by turning them clockwise and tightening them with the ratchet and socket.

10

Insert the square drive in the tensioner pulley. Route the serpentine belt around the pulleys in the same way it came off up to the tensioner pulley. Rotate the tensioner counterclockwise with the ratchet and slide the belt under it. Let the pulley come back and remove the ratchet.

11

Slide the lower radiator hose over the pump outlet nipple and slide the clamp to inch from the end. Tighten the clamp with the screwdriver by turning the worm screw clockwise.

12

Reinstall the fan assembly and shroud by sliding the fan over the water pump pulley studs. Thread the bolts onto the studs by turning them clockwise by hand. Tighten these bolts to approximately 20 foot-pounds. Secure the fan shroud to the radiator by inserting the bolts into the bolt holes and turning them clockwise. Tighten these bolts to approximately 20 foot-pounds. Close the radiator drain plug.

13

Refill the radiator with fresh coolant until the coolant reaches the lower edge of the inner neck. Start the engine and let it come to operating temperature. Refill the radiator as necessary. Check for leaks and reinstall the radiator cap by pushing it down and turning it clockwise until it stops.