Question about 1991 Chevrolet C1500

1 Answer

1991 chevy 1500 water pump removal

Im in the process of replacing the exhaust manifold gaskets on a chevy 1500. there is a bracket that attaches to the manifold, rear of the alternator and the back of the water pump. the only way (that i can see) to remove the bracket it to remove the water pump.
The source of fustration at the moment it the bolt on the fron of the water pump pullie that needs to be taken out so that the pillie can be taken off to get at the bolts to remove that water pump (just a little confusing eh?)

any way, the answer i want to get at is if the water pump pullie os crimped or pressed onto the bolt/shaft in the center, because as many diffrient ways i try to loosen the bolt (impact gun, allen key, tapping it to losen rust) it just seels to strip the bolt further (the bolt in question is a 3/8' allen socket)

hepl is very much apricaited)

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  • 2 more comments 
  • TransAm80boy Sep 04, 2008

    the block has been replaced, at the moment i can tell you the VIN letter, but it's a 350, throttle body injected

  • TransAm80boy Sep 04, 2008

    at the moment i can't tell you the VIN letter (@ work rite now) but it's a 350, throttle body intake

  • yadayada
    yadayada May 11, 2010

    What engine? makes a difference.

  • Anonymous Mar 28, 2014

    rear manifold

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  • 6 Answers

I'm not so certain you need to take that pulley off to get the water pump off. All the bolts should be accessible. Aren't there holes in the pulley that line up with any hidden bolts in behind? GM is well known for doing that. Rotate the pulley until you can sneak a socket through the pulley hole and get onto the bolts you need. (Unless this is a different design).

Posted on Mar 03, 2009

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  1. Disconnect the negative battery cable
  2. Detach the oxygen sensor connector.
  3. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for more complete coolant drain.
  4. Remove upper and lower exhaust manifold heat shields.
  5. Remove the bolt that attaches the exhaust manifold brace to the manifold.
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How to replace the exhaust manifold ring in my 91 Toyota Tercel


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WHAT ARE THE TORQUE SPECS FOR A WATER PUMP ON A 2003 CHEVY MALIBU


Water Pump REMOVAL & INSTALLATION CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. 2.4L Engine
  1. Disconnect the negative battery cable
  2. Detach the Oxygen (O2) sensor electrical connector.
  3. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for a more complete coolant drain.
  4. Remove upper exhaust manifold heat shield.
  5. Remove the bolt that attaches the exhaust manifold brace to the manifold.
  6. Remove the lower exhaust manifold heat shield.
  7. Break the manifold-to-exhaust pipe spring loaded bolts loose using a 13mm box wrench.
  8. Raise and safely support the vehicle. NOTE: It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.
  9. Unfasten the two radiator outlet pipe-to-water pump cover bolts.
  10. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
    1. Unscrew either bolt clockwise 4 turns.
    2. Remove the other bolt.
    3. Remove the first bolt. NOTE: DO NOT rotate the flex coupling more than 4°or damage may occur.
  11. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  12. Remove the radiator outlet pipe from the oil pan and transaxle. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump. Leave the radiator outlet pipe hang.
  13. Carefully lower the vehicle.
  14. Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
  15. Remove the front timing chain cover and the chain tensioner. For details, please refer to the procedure located later in this section.
  16. Unfasten the water pump-to-cylinder block bolts. Remove the water pump-to-timing chain housing nuts. Remove the water pump and cover mounting bolts and nuts. Remove the water pump and cover as an assembly, then separate the two pieces. Fig. 1: Water pump and cover mounting - 2.4L engine 87953070.gif
    To install:
  17. Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
  18. Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
  19. Lubricate the radiator outlet pipe O-ring with antifreeze and slide the pipe onto the water pump cover. Install the bolts finger-tight.
  20. With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
    1. Pump assembly-to-chain housing nuts:19 ft. lbs. (26 Nm).
    2. Pump cover-to-pump assembly: 106 inch lbs. (12 Nm).
    3. Cover-to-block, bottom bolt first: 19 ft. lbs. (26 Nm).
    4. Radiator outlet pipe assembly-to-pump cover: 125 inch lbs. (14 Nm).
  21. Using new gaskets, install the exhaust manifold. Make sure to following the tightening sequence and torque specifications given in the exhaust manifold procedure located in this section.
  22. Raise and safely support the vehicle.
  23. Index the exhaust manifold bolts into the exhaust pipe flange.
  24. Connect the exhaust pipe to the manifold. Install the exhaust pipe flange bolts evenly and gradually to avoid binding. Turn the bolts in until fully seated.
  25. Connect the radiator outlet pipe to the transaxle and oil pan.
  26. Install the timing chain tensioner and front cover.
  27. Install the lower heat shield.
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  29. Fasten the bolt that attaches the exhaust manifold brace to the manifold.
  30. Tighten the manifold-to-exhaust pipe nuts to specification.
  31. Install the upper heat shield.
  32. Attach the oxygen sensor connector.
  33. Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
  34. Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine OFF.
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3.1L Engine
  1. Disconnect the negative battery cable.
  2. Properly drain the cooling system into a suitable container.
  3. Loosen, but do not remove, the water pump pulley bolts.
  4. Remove the serpentine belt.
  5. Unfasten the water pump pulley bolts, then remove the pulley.
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  7. Clean all the gasket surfaces completely.
  8. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area, then install the gasket onto the water pump.
  9. Position the water pump on the engine, then tighten the water pump mounting bolts to 89 inch lbs. (10 Nm).
  10. Install the water pump pulley and finger-tighten the pulley bolts.
  11. Install the serpentine belt.
  12. Tighten the water pump pulley bolts to 18 ft. lbs. (25 Nm).
  13. Fill the cooling system.
  14. Connect the negative battery cable, then start the engine. Let the engine run until it reaches normal operating temperature, then check for leaks and coolant level. Add coolant, if necessary, then turn the engine OFF.
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Nov 03, 2010 | 2003 Chevrolet Malibu

1 Answer

Do i need to lift the engine up to acces the timeing chain cover to remove the water pump? on chev 1999 2.4l


Water Pump REMOVAL & INSTALLATION CAUTION
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  1. Disconnect the negative battery cable.
  2. Properly drain the cooling system into an approved container.
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  4. Remove the alternator and bracket. For details, please refer to Section 2 of this manual.
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  6. Unfasten the mounting bolts, then remove the water pump.
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    Fig. 2: If the pulley turns when you try to loosen the bolts, attach sockets and ratchets to two of the bolts, insert a prybar to hold the pulley in place and loosen the bolts - 2.2L engine 91113p41.jpg
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    Fig. 4: The water pump is retained by four bolts, remove them and . . . 91143p85.jpg
    Fig. 5: . . . remove the water pump from the engine 91143p86.jpg
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    Fig. 7: . . . the water pump (if it is being reused) 91143p89.jpg
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  8. Place a 1?8 in. (3mm) wide bead of RTV sealant on the water pump sealing surface or install a new gasket, on models so equipped. Install the pump and tighten the retaining bolts to 18 ft. lbs. (25 Nm).
  9. Install the water pump pulley, then tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  10. As outlined in Section 2, install the alternator and bracket.
  11. Install the drive belts or serpentine belt, as applicable.
  12. Fill the cooling system to the proper level.
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2.3L and 2.4L Engines
  1. Disconnect the negative battery cable
  2. Detach the oxygen sensor connector.
  3. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for more complete coolant drain.
  4. Remove upper exhaust manifold heat shield.
  5. Remove the bolt that attaches the exhaust manifold brace to the manifold.
  6. Remove the lower exhaust manifold heat shield.
  7. Break loose the manifold to exhaust pipe spring loaded bolts using a 13mm box wrench.
  8. Raise and safely support the vehicle. NOTE: It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.
  9. Unfasten the two radiator outlet pipe-to-water pump cover bolts.
  10. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
    1. Unscrew either bolt clockwise 4 turns.
    2. Remove the other bolt.
    3. Remove the first bolt. NOTE: On the 2.4L engines, DO NOT rotate the flex coupling more than 4°or damage may occur.
  11. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  12. Remove the radiator outlet pipe from the oil pan and transaxle. If equipped with a manual transaxle, remove the exhaust manifold brace. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump. Leave the radiator outlet pipe hang.
  13. Carefully lower the vehicle.
  14. Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
  15. For the 2.4L engine, remove the front timing chain cover and the chain tensioner. For details, please refer to the procedure located later in this section.
  16. Unfasten the water pump-to-cylinder block bolts. Remove the water pump-to-timing chain housing nuts. Remove the water pump and cover mounting bolts and nuts. Remove the water pump and cover as an assembly, then separate the two pieces. Fig. 9: Water pump and cover mounting - 2.3L and 2.4L engines 87953070.gif
    To install:
  17. Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
  18. Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
  19. Lubricate the radiator outlet pipe O-ring with antifreeze and slid the pipe onto the water pump cover. Install the bolts finger-tight.
  20. With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
    1. Pump assembly-to-chain housing nuts - 19 ft. lbs. (26 Nm).
    2. Pump cover-to-pump assembly - 106 inch lbs. (12 Nm).
    3. Cover-to-block, bottom bolt first - 19 ft. lbs. (26 Nm).
    4. Radiator outlet pipe assembly-to-pump cover - 125 inch lbs. (14 Nm).
  21. Using new gaskets, install the exhaust manifold. Make sure to following the tightening sequence and torque specifications given in the exhaust manifold procedure located in this section.
  22. Raise and safely support the vehicle.
  23. Index the exhaust manifold bolts into the exhaust pipe flange.
  24. Connect the exhaust pipe to the manifold. Install the exhaust pipe flange bolts evenly and gradually to avoid binding. Turn the bolts in until fully seated.
  25. Connect the radiator outlet pipe to the transaxle and oil pan. Install the exhaust manifold brace, if removed.
  26. On the 2.4L engine, install the timing chain tensioner and front cover.
  27. Install the lower heat shield.
  28. Carefully lower the vehicle.
  29. Fasten the bolt that attaches the exhaust manifold brace to the manifold.
  30. Tighten the manifold-to-exhaust pipe nuts to specification.
  31. Install the upper heat shield.
  32. Attach the oxygen sensor connector.
  33. Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
  34. Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine off.
  35. Once the vehicle has cooled, recheck the coolant level.
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Sep 18, 2010 | 1998 Chevrolet Cavalier

2 Answers

How to replace water pump on 97 pontiac sunfire 2.4


PLEASE DON'T FORGET TO RATE! THANKS! 2.3L & 2.4L Engines
  1. Disconnect the negative battery cable
  2. Detach the oxygen sensor connector.
  3. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for more complete coolant drain.
  4. Remove upper exhaust manifold heat shield.
  5. Remove the bolt that attaches the exhaust manifold brace to the manifold.
  6. Remove the lower exhaust manifold heat shield.
  7. Break loose the manifold to exhaust pipe spring loaded bolts using a 13mm box wrench.
  8. Raise and safely support the vehicle.
It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.
  1. Unfasten the two radiator outlet pipe-to-water pump cover bolts.
  2. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
    1. Unscrew either bolt clockwise 4 turns.
    2. Remove the other bolt.
    3. Remove the first bolt.
On the 2.4L engines, DO NOT rotate the flex coupling more than 4° or damage may occur.
  1. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  2. Remove the radiator outlet pipe from the oil pan and transaxle. If equipped with a manual transaxle, remove the exhaust manifold brace. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump. Leave the radiator outlet pipe hang.
  3. Carefully lower the vehicle.
  4. Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
  5. For the 2.4L engine, remove the front timing chain cover and the chain tensioner. For details, please refer to the procedure located later in this section.
  6. Unfasten the water pump-to-cylinder block bolts. Remove the water pump-to-timing chain housing nuts. Remove the water pump and cover mounting bolts and nuts. Remove the water pump and cover as an assembly, then separate the two pieces.

01add58.gif
Water pump and cover mounting-2.3L and 2.4L engines

To install:
  1. Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
  2. Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
  3. Lubricate the radiator outlet pipe O-ring with antifreeze and slid the pipe onto the water pump cover. Install the bolts finger-tight.
  4. With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
    1. Pump assembly-to-chain housing nuts-19 ft. lbs. (26 Nm).
    2. Pump cover-to-pump assembly-106 inch lbs. (12 Nm).
    3. Cover-to-block, bottom bolt first-19 ft. lbs. (26 Nm).
    4. Radiator outlet pipe assembly-to-pump cover-125 inch lbs. (14 Nm).
  5. Using new gaskets, install the exhaust manifold. Make sure to following the tightening sequence and torque specifications given in the exhaust manifold procedure located in this section.
  6. Raise and safely support the vehicle.
  7. Index the exhaust manifold bolts into the exhaust pipe flange.
  8. Connect the exhaust pipe to the manifold. Install the exhaust pipe flange bolts evenly and gradually to avoid binding. Turn the bolts in until fully seated.
  9. Connect the radiator outlet pipe to the transaxle and oil pan. Install the exhaust manifold brace, if removed.
  10. On the 2.4L engine, install the timing chain tensioner and front cover.
  11. Install the lower heat shield.
  12. Carefully lower the vehicle.
  13. Fasten the bolt that attaches the exhaust manifold brace to the manifold.
  14. Tighten the manifold-to-exhaust pipe nuts to specification.
  15. Install the upper heat shield.
  16. Attach the oxygen sensor connector.
  17. Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
  18. Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine off.
  19. Once the vehicle has cooled, recheck the coolant level.

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1 Answer

How to replace head gasket on 1999 2.5 cyl ford ranger


Cylinder Head Removal
  1. Disconnect the battery ground cable
  2. Relieve the fuel pressure.
  3. Drain the cooling system. Disconnect the three way catalytic converter Loosen the water pump pulley bolts.
  4. Remove the drive belt.
  5. Remove the water pump pulley, fan and clutch assembly.
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Installation
  1. Clean all gasket mating surfaces.
  1. Install new gaskets as necessary.
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  1. Follow the removal procedure in reverse order.
  1. Tighten the bolts in sequence, in three stages, to 70 Nm (51 lb/ft).
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    • Stage 3: Tighten all bolts an additional 90-100 degrees.
  2. Install generator bracket. Install bolts in four stages.
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    • Stage 2: Install and tighten bolt 2.
    • Stage 3: Install and tighten bolt 3.
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1 Answer

How do i change a water pump in a 97 grand am with a 2.4 litre engine


2.4L Engine
See Figure 3
  1. Disconnect the negative battery cable.
  2. Drain and recycle the engine coolant.
  3. Disconnect the oxygen sensor wiring.
  4. Remove the upper exhaust manifold heat shield.
  5. Raise and safely support the front end of the vehicle securely on jackstands.
  6. Remove the exhaust manifold brace bolt.
  7. Unbolt and remove the lower exhaust manifold heat shield.
  8. Break loose the manifold-to-exhaust pipe spring loaded nuts.
  9. Unbolt the radiator outlet pipe assembly from the water pump cover.
  10. Disconnect the exhaust pipe from the manifold.
  11. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
Do not rotate the flex coupling more than 4°. this could damage the component.
  1. Separate the radiator outlet pipe from the oil pan and transaxle.
    1. On manual transaxle, remove the exhaust manifold brace.

  2. Next, leave the lower radiator hose attached and pull down on the outlet pipe to detach it from the water pump. Allow the outlet pipe to hang.
  3. Lower the vehicle.
  4. Remove the exhaust manifold-to-cylinder head nuts.
  5. Extract the manifold, seals and gaskets.
  6. Remove the timing chain cover. Refer to the procedure later on in this section.
  7. Remove the timing chain tensioner. Refer to Timing Chain removal later in this section.
  8. Unbolt the water pump from the cylinder block.
  9. Extract the pump assembly-to-timing chain housing nuts.
  10. Remove the water pump and cover assembly.
  11. Separate the pump from the cover.
  12. Clean all mating surfaces of gaskets and sealant materials.

To install:
Prior to installing the water pump, read the entire procedure. Pay special attention to the tightening sequence to avoid component damage and ensure a proper seal.
  1. Attach the water pump to the cover and hand-tighten the components.
  2. Lubricate the splines of the water pump drive with chassis grease or equivalent, then install the pump and cover assembly. Hand tighten the cover-to-block bolts.
  3. Install the pump-to-chain housing nuts and hand-tighten.
  4. Lubricate the O-ring on the radiator outlet pipe with an anti-freeze solution and slide the pipe into the water pump cover, install and hand-tighten the bolts.
  5. With the specified gaps, tighten in sequence as follows:
    1. Pump assembly-to-chain housing nuts
    2. Pump cover-to-pump assembly
    3. Cover-to-block, bottom bolt first
    4. Radiator outlet pipe assembly-to-cover

  6. Install the exhaust manifold using new gaskets.
  7. Install the manifold-to-cylinder head nuts, follow the tightening sequence and tighten to specifications.
  8. Raise and support the front of the vehicle.
  9. Index the exhaust manifold-to-exhaust pipe flange bolts.
    1. Turn bolt bolts in evenly to avoid cocking the exhaust pipe and binding the bolts. Turn the bolts in until they are fully seated.

  10. Install and secure the radiator outlet pipe to the transaxle and oil pan.

On manual transaxles, install the exhaust manifold brace.
  1. Install the timing chain tensioner and chain cover.
  2. Attach the lower heat shield.
  3. Lower the vehicle.
  4. Attach the exhaust manifold brace. Tighten the manifold-to-exhaust pipe nuts to specification.
  5. Attach and secure the upper heat shield.
  6. Connect the oxygen sensor wiring.
  7. Fill the radiator with coolant water mixture until it reaches the heater hose coolant outlet, then install the hose and continue to fill. This will assist with the complete cylinder block fill.
  8. Connect the negative battery cable.
  9. Start the engine and top off the cooling system and check for leaks.
ec6ae2e.jpg

Dec 28, 2009 | 1997 Pontiac Grand Am

1 Answer

Need to know how to remove starter from 1991 dodge caravan


e
26065b4.jpg

Starter motor mounting-2.2L and 2.5L engines

- Working from under the vehicle, disconnect the starter motor heat shield clamp

fb70ec4.jpg

View of the starter motor with the heat shield removed while looking over the crossmember

-
Removing the starter motor mounting stud nut where the air pump tube bracket is also attached

  1. Disconnect the negative battery cable.
  2. Raise and safely support the vehicle. The starter can be removed by reaching over the crossmember.
  3. Remove the heat shield and its clamps, if so equipped.
  4. On the 2.2L and 2.5L engines, loosen the air pump tube at the exhaust manifold and move the tube bracket away from the starter.
  5. Remove the electrical connections from the starter.
  6. Remove the bolts attaching the starter to the flywheel housing and the rear bracket to the engine or transaxle.
  7. Remove the starter from the engine.

To install:
  1. Position the replacement starter against the mounting surface.
  2. Install the mounting bolts.
  3. Connect the starter wiring.
  4. On 2.2L and 2.5L engines, position the air pump tube toward the starter, then connect the tube bracket to the exhaust manifold.
  5. Install the heat shield and clamp.
  6. Connect the negative battery cable.

Hope helped with this (remember rated this help) Good luck.

Nov 03, 2009 | 1991 Dodge Caravan

1 Answer

Replacing the water pump


2.4L Engine
  1. Disconnect the negative battery cable
  2. Detach the Oxygen (O2) sensor electrical connector.
  3. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for a more complete coolant drain.
  4. Remove upper exhaust manifold heat shield.
  5. Remove the bolt that attaches the exhaust manifold brace to the manifold.
  6. Remove the lower exhaust manifold heat shield.
  7. Break the manifold-to-exhaust pipe spring loaded bolts loose using a 13mm box wrench.
  8. Raise and safely support the vehicle.

NOTE It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.
  1. Unfasten the two radiator outlet pipe-to-water pump cover bolts.
  2. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
    1. Unscrew either bolt clockwise 4 turns.
    2. Remove the other bolt.
    3. Remove the first bolt.

NOTE DO NOT rotate the flex coupling more than 4° or damage may occur.
  1. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  2. Remove the radiator outlet pipe from the oil pan and transaxle. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump. Leave the radiator outlet pipe hang.
  3. Carefully lower the vehicle.
  4. Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
  5. Remove the front timing chain cover and the chain tensioner. For details, please refer to the procedure located later in this section.
  6. Unfasten the water pump-to-cylinder block bolts. Remove the water pump-to-timing chain housing nuts. Remove the water pump and cover mounting bolts and nuts. Remove the water pump and cover as an assembly, then separate the two pieces.
87953070.gif Water pump and cover mounting—2.4L engine
Click to Enlarge
To install:
  1. Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
  2. Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
  3. Lubricate the radiator outlet pipe O-ring with antifreeze and slide the pipe onto the water pump cover. Install the bolts finger-tight.
  4. With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
    1. Pump assembly-to-chain housing nuts:19 ft. lbs. (26 Nm).
    2. Pump cover-to-pump assembly: 106 inch lbs. (12 Nm).
    3. Cover-to-block, bottom bolt first: 19 ft. lbs. (26 Nm).
    4. Radiator outlet pipe assembly-to-pump cover: 125 inch lbs. (14 Nm).
  5. Using new gaskets, install the exhaust manifold. Make sure to following the tightening sequence and torque specifications given in the exhaust manifold procedure located in this section.
  6. Raise and safely support the vehicle.
  7. Index the exhaust manifold bolts into the exhaust pipe flange.
  8. Connect the exhaust pipe to the manifold. Install the exhaust pipe flange bolts evenly and gradually to avoid binding. Turn the bolts in until fully seated.
  9. Connect the radiator outlet pipe to the transaxle and oil pan.
  10. Install the timing chain tensioner and front cover.
  11. Install the lower heat shield.
  12. Carefully lower the vehicle.
  13. Fasten the bolt that attaches the exhaust manifold brace to the manifold.
  14. Tighten the manifold-to-exhaust pipe nuts to specification.
  15. Install the upper heat shield.
  16. Attach the oxygen sensor connector.
  17. Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
  18. Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine OFF.
  19. Once the vehicle has cooled, recheck the coolant level, then install the radiator cap.

3.1L Engine
  1. Disconnect the negative battery cable.
  2. Properly drain the cooling system into a suitable container.
  3. Loosen, but do not remove, the water pump pulley bolts.
  4. Remove the serpentine belt.
  5. Unfasten the water pump pulley bolts, then remove the pulley.
  6. Remove the five water pump mounting bolts, then remove the water pump.
To install:
86883115.gif View of the water pump mounting and bolt tightening specifications—3.1L engine shown
Click to Enlarge
  1. Clean all the gasket surfaces completely.
  2. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area, then install the gasket onto the water pump.
  3. Position the water pump on the engine, then tighten the water pump mounting bolts to 89 inch lbs. (10 Nm).
  4. Install the water pump pulley and finger-tighten the pulley bolts.
  5. Install the serpentine belt.
  6. Tighten the water pump pulley bolts to 18 ft. lbs. (25 Nm).
  7. Fill the cooling system.
  8. Connect the negative battery cable, then start the engine. Let the engine run until it reaches normal operating temperature, then check for leaks and coolant level. Add coolant, if necessary, then turn the engine OFF.

Aug 20, 2009 | 1997 Chevrolet Malibu

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