Coolant Pump Manifold Replacement

Coolant Pump Manifold Replacement (RPO LS4)

Removal Procedure




1. Drain the cooling system.
2. Loosen the water pump bolts (318).
3. Remove the drive belt.
4. Remove fluid from the power steering pump reservoir.
5. Remove the power steering pump pulley.
6. Disconnect the power steering hoses and pipes from the power steering pump and reservoir.
7. Remove the bolt that retains a clip that retains the pressure pipe to the front of the engine.
8. Remove the water pump bolts (318).
9. Remove the water pump (300) and gasket (314). Discard the gasket.
10. Remove the camshaft position sensor.
11. Unclip the wiring harness from the front of the engine.




12. Disconnect the engine coolant air bleed pipe hoses and clamps.
13. Remove the three coolant pump manifold to cylinder head bolts.
14. Disconnect the heater hoses at the coolant pump manifold.
15. Disconnect the radiator hoses from the coolant pump manifold.
16. Remove the coolant pump manifold bolts (301).
17. Remove the coolant pump manifold (315) and gaskets (306). Discard the gaskets.
18. Clean and inspect the water pump manifold mounting surfaces.




19. Remove the thermostat housing bolts (302), if necessary.
20. Remove the thermostat housing (303) and O-ring seal (304), if necessary.
21. Remove the thermostat (305), if necessary.
22. Remove the power steering pump and reservoir from the coolant pump manifold.
23. Remove the drive belt idler pulleys from the coolant pump manifold.

Installation Procedure

Notice: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly.

Important: All gasket surfaces are to be free of oil and other foreign material during assembly.




1. Install the drive belt idler pulleys to the coolant pump manifold.
2. Install the power steering pump and reservoir to the coolant pump manifold.
3. Install the thermostat (305), if necessary.
4. Install the thermostat housing (303) and O-ring seal (304), if necessary.

Notice: Refer to Fastener Notice.

5. Install the thermostat housing bolts (302), if necessary.

Tighten the bolts to 15 N.m (11 lb ft).




6. Install the water pump manifold (315) and NEW gaskets (306).
1. Tighten the M10 bolts to 60 N.m (44 lb ft).
2. Tighten the M8 bolts to 30 N.m (22 lb ft).
7. Install the water pump manifold bolts (301).
8. Install the camshaft position sensor.
9. Install the cylinder head to coolant pump manifold bolts.
10. Connect the engine coolant air bleed pipe hose and clamp.




11. Install the water pump (300) and a NEW gasket (314).
12. Install the water pump bolts (318) until sung.
13. Connect the power steering pipes and hoses to the pump and reservoir.
14. Install the power steering pump pulley.
15. Install the bolt that retains the power steering pipe to the front of the engine.
16. Install the wiring harness to the clips on the front of the engine.
17. Install the drive belt.

Tighten the bolts to 10 N.m (89 lb in).

19. Connect the heater hoses to the coolant pump manifold.
20. Connect the radiator hoses to the coolant pump manifold.
21. Fill and bleed the power steering system.
22. Fill the cooling system.