I replaced a water pump in my '97 TJ 2.5L jeep last weekend at 128,600 miles. While I was at it, I replaced the upper and lower hoses as well. I ordered the Jeep service manual from Daimler Chrysler just prior to undertaking the task.
Has anyone in this group ever replaced a water pump on this model? The reason I ask is because of the Power Steering pump bracket and how much of a pain it was.
To those who aren't aware, the power steering pump bracket is attached to the water pump, so you must unbolt the power steering pump, then unbolt the power steering pump bracket to get the water pump out. The manual says to completely remove the bracket altogether, but the graphic that it shows isn't accurate. It shows the bracket attached with three simple bolts. In reality, the two front bolts are simple, but the third lower attachment is another story. There, a little flange is sandwiched between the engine block and a major engine attachment fitting, connecting the engine to the frame and this sandwiched flange is further affixed with a funky stud/nut type fastener (a stud with a nut fixed on it somehow). I took this funky fastener out, but there was no way to get the bracket out because this little flange was smashed between the motor mount and the engine. If I got it out, I knew I'd never get it back in.
I ended up replacing the nut/stud, removed the two front bolts, and just bending the bracket out of the way so I could get the water pump out.
I replaced the pump, but then had MAJOR problems with the bracket because I couldn't get the holes in the bracket to line up properly with the holes in the pump. The pump is cast aluminum I believe. With the bracket bolts not lining up perfectly, I began to cross thread the bolts as I tried to screw them into the tapped holes on the pump. I pulled and pushed and tugged that bracket for at least and hour trying to get it back into its original shape. By screwing a bolt into the back side of the upper hole, thereby reforming the theads, I finally got one bolt back in, but the lower one I had to leave out. I looks like it is running fine.
I am interested in hearing about how others have handled replacing a water pump on this engine.
Thanks,
-Trent