Water Pump

Replace the water pump on a 1992 Dodge Viper 8.0L V10 by draining coolant, removing accessory drive components, and installing a new pump with fresh gasket.

Warnings

Tools required

Parts

• Water pump with gasket × 1 — Use OEM specification
• Serpentine drive belt × 1 — Use OEM specification
• Coolant (ethylene glycol 50/50 premix) × 1 — Use OEM specification

Fluids

• coolant — 24 qt

Preparation

1. Park vehicle on level surface and allow engine to cool completely (minimum 2 hours after operation)
2. Disconnect negative battery cable
3. Raise front of vehicle and secure on jack stands rated for vehicle weight
4. Remove front undertray panels if equipped to access lower radiator area
5. Place drain pan under radiator drain petcock location

Procedure

1. 1

   Drain Cooling System
   Open radiator drain petcock located at the bottom of the radiator and drain coolant into collection pan. Once flow stops, remove radiator cap to allow complete drainage. If radiator does not have drain petcock, disconnect lower radiator hose at radiator. Collect and dispose of coolant according to local regulations.
2. 2

   Remove Serpentine Belt
   Locate the serpentine belt tensioner on the driver side of the engine. Using a serpentine belt tool or 1/2" breaker bar, rotate the tensioner clockwise to release tension. Slide the belt off the pulleys and carefully release tensioner. Remove belt from engine bay. Inspect belt for wear, cracking, or glazing; replacement is recommended during water pump service.
3. 3

   Disconnect Radiator Hoses
   Locate upper radiator hose connection at the thermostat/coolant outlet housing (verify exact location per factory service manual). Release hose clamp and remove upper hose. Locate lower radiator hose connection at the water pump inlet (verify exact routing per factory service manual). Release hose clamp and remove lower hose. Be prepared for residual coolant spillage. Inspect hoses for cracks, swelling, or deterioration.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Remove Heater Hose Connections
   Identify heater hoses in the water pump / coolant crossover area (verify exact connection points per factory service manual). Release hose clamps using pliers or appropriate tool. Disconnect both heater hoses from water pump. Cap or plug hose ends to prevent additional coolant loss.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
5. 5

   Remove Water Pump Pulley
   While water pump is still secured to engine block, remove the water pump pulley mounting bolts (typically 4 bolts). Holding the pulley to prevent rotation, remove all pulley bolts and set aside. Remove pulley from water pump shaft. If pulley is press-fit, a pulley puller may be required.
6. 6

   Remove Accessory Brackets if Necessary
   Depending on accessory configuration, the alternator bracket or idler pulley bracket may obstruct water pump removal. Inspect the water pump mounting area and identify any brackets that must be removed. Remove mounting bolts for obstructing brackets and reposition or remove brackets to provide clearance for water pump removal.
   ℹ️Early production 1992 Vipers may have different accessory bracket configurations than later production. Verify bracket interference before proceeding.
7. 7

   Remove Water Pump Mounting Bolts
   Locate all water pump mounting bolts around the perimeter of the pump. Remove the 8 bolts securing water pump to engine block in a criss-cross pattern to prevent warping. Keep bolts organized by location as some may be different lengths.
8. 8

   Remove Water Pump
   With all mounting bolts removed, carefully pull water pump away from engine block. If pump is stuck due to gasket seal, use a small pry bar against casting ears (not sealing surfaces) to break seal. Remove water pump from engine bay. Be prepared for residual coolant spillage from pump cavity and block.
9. 9

   Clean Mounting Surface
   Using a plastic gasket scraper, carefully remove all old gasket material from engine block water pump mounting surface. Ensure surface is completely clean and free of debris, corrosion, or old gasket residue. Use wire brush on stubborn areas, being careful not to gouge aluminum surface. Wipe surface clean with lint-free cloth. Inspect mounting surface for cracks, corrosion, or damage.
10. 10

    Install New Water Pump
    Position new gasket on water pump or engine block mounting surface according to gasket manufacturer instructions (some gaskets use sealant, others are dry installation). Align new water pump with mounting holes and carefully position against engine block. Start all mounting bolts by hand to ensure proper alignment. Once all bolts are started, tighten in a criss-cross pattern to the factory-specified torque (verify exact value per factory service manual before final tightening).
    ⚠Do not over-torque water pump bolts. Excessive torque can crack the pump housing or warp the mounting flange, causing coolant leaks.
    Torque spec

    Water Pump Bolts25 Nm (18 lb-ft)
11. 11

    Reinstall Water Pump Pulley
    Position water pump pulley on pump shaft. Install pulley mounting bolts and tighten in a star pattern while holding pulley to prevent rotation. Torque pulley bolts to manufacturer specification.
12. 12

    Reinstall Accessory Brackets
    If any accessory brackets were removed in step 6, reinstall them now in reverse order of removal. Torque bracket bolts to manufacturer specifications. Ensure all brackets are properly seated and secured before proceeding.
13. 13

    Reconnect Coolant Hoses
    Reconnect lower radiator hose to water pump inlet and secure with hose clamp. Reconnect upper radiator hose to thermostat housing and secure with hose clamp. Reconnect both heater hoses to water pump connections and secure with hose clamps. Ensure all hose connections are fully seated before tightening clamps.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
14. 14

    Install Serpentine Belt
    Route new serpentine belt around all pulleys according to belt routing diagram (typically located on radiator support or underhood decal). Using belt tool or breaker bar, rotate tensioner clockwise and slide belt onto final pulley. Carefully release tensioner to apply proper belt tension. Verify belt is properly seated in all pulley grooves.
15. 15

    Refill Cooling System and Bleed Air
    Close radiator drain petcock or reconnect lower radiator hose if removed for draining. Using a 50/50 premix of ethylene glycol coolant, slowly fill cooling system through radiator cap opening. Fill until coolant level reaches bottom of radiator neck. Start engine and allow to idle with radiator cap off. As engine warms and thermostat opens, coolant level will drop; continue adding coolant to maintain level. Run engine until cooling fans cycle on, indicating full operating temperature. Check for leaks around water pump and all hose connections. Once fans cycle, shut off engine and allow to cool slightly. Top off coolant to proper level and install radiator cap. Check overflow reservoir and fill to cold fill line.
    ⚠Watch for coolant leaks during initial warm-up. Shut off engine immediately if leaks are observed.

Reassembly

1. Reinstall any front undertray panels removed during preparation
2. Lower vehicle from jack stands
3. Reconnect negative battery cable
4. Start engine and verify no coolant leaks after reaching operating temperature
5. Recheck coolant level after first drive cycle when engine is cool

Verification

• Check for coolant leaks around water pump mounting surface, hose connections, and gasket areas with engine at operating temperature
• Verify proper coolant circulation by confirming both radiator hoses become hot after thermostat opens
• Confirm cooling fans cycle on and off properly at normal operating temperature
• Check coolant level in both radiator and overflow reservoir; top off if needed
• Verify serpentine belt tracking is centered on all pulleys with no unusual noise
• Test drive vehicle and monitor temperature gauge for normal operation
• Recheck coolant level after vehicle has cooled from test drive

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