🔧 Savana - Water Pump Replacement

The water pump moves coolant through the engine and radiator to prevent overheating. Replacing it involves draining coolant, removing the fan and belt, swapping the pump and gasket, then refilling and bleeding the cooling system.

Difficulty Level: Advanced | Estimated Time: 2.5-4.0 hours

Assumption: Factory mechanical fan + clutch (most Savana vans).

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⚠️ Safety & Precautions

• ⚠️ Let the engine cool fully before opening the coolant cap.
• ⚠️ Wear safety glasses and gloves; coolant is harmful and slippery.
• ⚠️ Keep hands/tools clear of the fan and belt area.
• ⚠️ Use jack stands if you lift the front; never rely on a jack alone.
• ⚠️ Disconnect the negative battery cable if your hands will be near the fan while working.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Drain pan (at least 4-gallon)
• Funnel
• Shop rags
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 3/8" drive ratchet
• 1/2" drive ratchet
• 3/8" drive extension set
• 10mm socket
• 13mm socket
• 15mm socket
• Flathead screwdriver
• Hose clamp pliers
• Torque wrench (10–100 ft-lbs range)
• 36mm fan clutch wrench (specialty)
• Fan pulley holding tool (specialty)
• Plastic razor scraper

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Water pump - Qty: 1
• Water pump gasket/seal - Qty: 1
• Dex-Cool coolant (orange) 50/50 premix - Qty: 3-4 gallons
• Hose clamp(s) assorted - Qty: 1-2
• Serpentine belt - Qty: 1

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📋 Before You Begin

• 🅿️ Park on level ground, set the parking brake, and chock the rear wheels.
• 🧊 Confirm the engine is cold to the touch before starting.
• 🔋 If you choose to disconnect power: use a 10mm socket to remove the negative battery cable and isolate it so it can’t spring back.
• 🧼 Have rags ready; coolant will spill when hoses come off.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve pressure and drain coolant

• Remove the coolant reservoir cap slowly by hand (only when cold).
• Place a drain pan (at least 4-gallon) under the radiator drain area.
• Open the drain and let coolant flow into the pan. Use a flathead screwdriver if your drain uses a slotted screw head.

Step 2: Remove the engine cover/air ducting (as needed)

• Loosen intake duct clamps using a flathead screwdriver.
• Remove any small bolts/clips using a 10mm socket.
• Move the ducting aside to create working room at the front of the engine.

Step 3: Remove the fan shroud

• Remove the shroud fasteners using a 10mm socket.
• Lift the shroud upward carefully to free it from the radiator tabs.

Step 4: Remove the mechanical fan and clutch

• Install the fan pulley holding tool (specialty) to keep the water-pump pulley from turning. (This tool holds the pulley still while you loosen the fan nut.)
• Use a 36mm fan clutch wrench (specialty) on the fan clutch nut and turn counterclockwise to loosen.
• Lift the fan/clutch assembly out carefully; the fins are sharp and the radiator is easy to damage.

Step 5: Remove the serpentine belt

• Use a 15mm socket on the belt tensioner bolt and rotate the tensioner to release belt tension.
• Slip the belt off and note the routing. Snap a quick photo first.

Step 6: Remove the water pump pulley

• Remove the pulley bolts using a 13mm socket.
• Remove the pulley and set it aside.

Step 7: Disconnect hoses from the water pump

• Use hose clamp pliers to compress and slide the clamps back.
• Twist the hoses gently by hand to break them free, then pull them off the pump.
• Catch remaining coolant in the drain pan and wipe spills with shop rags.

Step 8: Remove the water pump

• Remove the water pump bolts using a 13mm socket and 3/8" drive extension set.
• Pull the water pump straight forward and off the engine.
• Remove the old gasket/seal.

Step 9: Clean the mating surface

• Use a plastic razor scraper to clean the engine’s sealing surface.
• Wipe the surface clean with shop rags. No gouges, no leftover gasket.

Step 10: Install the new water pump and gasket

• Place the new gasket/seal on the new pump (match orientation).
• Position the pump and start all bolts by hand.
• Tighten bolts evenly with a 13mm socket.
• Final tighten with a torque wrench: Torque to 30 Nm (22 ft-lbs).

Step 11: Reinstall pulley, belt, fan, and shroud

• Install the water pump pulley and bolts using a 13mm socket.
• Snug the pulley bolts evenly, then final tighten with a torque wrench: Torque to 25 Nm (18 ft-lbs).
• Route the belt and rotate the tensioner with a 15mm socket to install the belt.
• Thread the fan clutch back on by hand first, then tighten using the 36mm fan clutch wrench (specialty) while holding the pulley with the fan pulley holding tool (specialty).
• Reinstall the fan shroud using a 10mm socket.
• Reinstall intake ducting and clamps using a flathead screwdriver and 10mm socket as needed.

Step 12: Refill coolant

• Pour Dex-Cool coolant (orange) 50/50 premix into the reservoir using a funnel until it reaches the COLD line.
• If you disconnected it, reconnect the negative battery cable using a 10mm socket.

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✅ After Repair

• 🧪 Start the engine and set the heater to MAX HEAT; let it idle and watch the temperature gauge.
• 🧯 Check for leaks at the water pump seam and hose connections while it runs.
• 🌡️ Once the engine reaches operating temperature and the heater blows hot, shut it off and let it cool fully.
• 🧴 Recheck coolant level and top off to the COLD line using Dex-Cool coolant (orange) 50/50 premix.
• 🔁 Over the next 1–2 drives, recheck the level and look for any drips under the front of the van.

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💰 DIY vs Shop Cost

Shop Cost: $550-$950 (parts + labor)

DIY Cost: $120-$260 (parts only)

You Save: $430-$690 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2.5-4.0 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.