1.03.016 GM 5.7 (350) Water Pump removal and installation procedure

This Policy is completed and is waiting on Field Service, Engineering, and Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for removing and installing the engine water pump on General Motors 5.7 Vortec style engines as laid out in this procedure.

Procedure

This procedure applies to all General Motors 5.7 Vortec style engines on Flogistix skids equipped with the General Motors 5.7 Vortec engine drive units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards.  Flogistix Service Technicians will perform the torque procedure as outlined in this procedure.  

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

If the threaded Fan Hub needs to be removed from the Water Pump shaft follow the link for the correct procedure to remove the Fan Hub

1.03.019 GM 5.7 (350) Water Pump Fan Hub removal and installation procedure 

GM 5.7 Water pump removal procedure

Remove the water pump and bolts.

After removing the engine water pump inspect the water pump for any of the following:

1. Remove all old gasket material from the water pump sealing surfaces

2. Clean all dirt and any debris from the water pump

Inspect the water pump for the following:

1. Leakage or damage to the housing cover or gasket

2. Excessive scratches or gouging to the gasket sealing surface

3. Leakage from the water pump vent hole      **A stain around the vent hole is acceptable.  If leakage occurred (dripping) with the engine operating and the cooling system pressurized, then replace the water pump

4. Damaged bolt hole threads.

5. Excessive side-to-side movement

6. Leakage around the water inlet pipe

7. Leakage around the heater hose pipe where it meets or attaches to the water pump housing.  **This pipe can be replaced by removing and taping the hole with a 3/8" NPT pipe tap.

GM 5.7 Waterpump installation procedure

Install the Engine Water pump.

If reusing the water pump bolts clean the thread surface and apply a sealant to the threads of the water pump bolts.

Install the water pump and NEW water pump gaskets

Install all the water pump bolts

Tighten the water pump bolts hand tight making sure the water pump is fully mated to the front of the engine block surface.

Torque the water pump bolts to 33 lb ft

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all General Motors 5.7 Vortec style Natural Gas Engines and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust.  Employees should be aware that units could contain flammable and toxic gasses.  Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment.  Risk of possible concentration of H2S.  Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.  

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.  

Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3 

This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools 

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing this procedure shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools to include metric sockets

• Torque Wrench capable of torquing 33 ft lbs   (Foot Pounds)

Approvals

Field Service approved by:

Date:

Engineering approved by: 

Date: 

EHSS approved by:

Date: