Question about 1996 Ford Windstar

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Chipped pistons on a caravelle 2.6i

We recently had a new reconditioned engine installed in our 1996 2.6i caravelle. We replaced radiator, did the exhaust and used all new and orif\ginal parts. At her 1000km we did a oil change and fitted a new oil filter. She ran perfect. There were no oil leaks, the temperature was perfect and she purred like a kitten. At about 2000km, we noticed that she was smoking at the exhaust. We took her back to the garage and they investigated. Two of the pistons had been chipped. What could have caused this as we would like to know before we carry on as we do not want the same problem to happen

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6ya6ya
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SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi,
a 6ya Mechanic can help you resolve that issue over the phone in a minute or two.
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Posted on Jan 02, 2017

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justuscc
  • 360 Answers

SOURCE: 98 f150 4.2 110.000 miles went to start up engine started clacking and smoking out exhaust

the intakes go bad on these engines....... they leak coolant in the cylinders and cause a hydro lock that causes the rods to bend making the piston skirt hit the crank......" clicking noise" theres a law suit in progress for this issue......... you can find info on the internet

Posted on Oct 15, 2008

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  • 157 Answers

SOURCE: 2.3l ranger keeps overheating, been through two radiators already.

Hello Ranger Joe, eight months and two radiators is very uncommon. Question, Have you visually confirmed the leak in the radiators or is the leak near the hose connections? Replacing the radiator, cap, water pump, & the thermostat leaves only two others, the hoses and the engine block/heads. Far fitched will be something or somebody poking holes in the radiator.

Posted on Nov 07, 2008

dealt_soul
  • 296 Answers

SOURCE: Oil Leak Valve Cover

If it is leaking around the valve cover then that is the problem. Just remove the bolts from the valve cover in a cross pattern (ex. back right - front left and go back and foward and work till you make it to the middle. Go purcahse a valve gasket for both right and left and replace them. Tighten in the same cross pattern and be careful no to pinch the gasket.

Posted on Feb 15, 2009

  • 29 Answers

SOURCE: when idleing it purs like

It probably needs an idle control valve.

Posted on Feb 22, 2011

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1 Answer

Diragram on how to change the water pump on a 1995 z24 cavalier 2.3


Check this procedure, according with the repair guide for...

2.3L and 2.4L Engines
(see Figure 9)
  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.Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  1. 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.
  2. Carefully lower the vehicle.
  3. Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
  4. 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.
  5. 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.

zjlimited_2033.jpg

Fig. 9: Water pump and cover mounting - 2.3L and 2.4L engines (click over image for zoom)

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.

Hope helps; remember to rating this answer and leave a testimonial comment. Thank you for using FixYa.

Oct 13, 2011 | 1995 Chevrolet Cavalier

1 Answer

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.
  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, 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: Fig. 2: View of the water pump mounting and bolt tightening specifications - 3.1L engine shown 86883115.gif

  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

I need a manual for an 87 Plymouth Caravelle. I need to replace the oxygen sensor to pass emissions testing and I'm trying to do it myself. It seems pretty easy but I need to figure out exactly where the...


Just follow your exhaust manifold from engine to where it connects to exhaust pipe. It should be right above that, threaded in to exhaust manifold.

Nov 03, 2010 | 1987 Plymouth Caravelle

1 Answer

How do I replace a water pump on a 1999 malibou with a quad 4?


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.
  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, then install the radiator cap.

Oct 26, 2010 | 1999 Chevrolet Malibu

1 Answer

I cant find where the thermostat goes to replace it on a 2.4L engine. For a buick skylark


Very odd arrangement. You have to reach thru the exhaust manifold. I will paste instructions from Autozone.com below.

  1. Disconnect the negative battery cable.
  2. Properly drain and recover the coolant to a level below the thermostat.
  3. Unfasten the coolant inlet housing bolt, which is accessible through the exhaust manifold.

d8f2a03.jpg

Fig. Fig. 5: View of the thermostat and related components-2.4L engine

  1. Raise and safely support the vehicle.
  2. Remove the radiator outlet pipe stud.
  3. Remove the second coolant inlet housing bolt, then remove the coolant inlet housing.
  4. Remove the thermostat, then clean the old gasket material from the mating surfaces.

To install:
  1. Position the thermostat in its correct location, then install the coolant inlet housing using a new gasket. Tighten the retaining bolt to 19 ft. lbs. (26 Nm) on the 2.3L and 10 ft. lbs. (14 Nm) on the 2.4L engine.
  2. Install the radiator outlet pipe stud.
  3. Carefully lower the vehicle.
  4. Install the coolant inlet housing bolt through the exhaust manifold.
  5. Properly fill the cooling system.
  6. Connect the negative battery cable, remove the radiator cap, then start the engine. Allow the engine to run with radiator cap removed, until the upper radiator hose becomes hot (thermostat open). With the engine idling, add coolant to the radiator until the level is up to the bottom of the filler neck.
  7. Install the radiator cap, making sure the arrows line up with the overflow tube.

Sep 19, 2010 | 1998 Pontiac Grand Am

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
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. 2.2L Engine
  1. Disconnect the negative battery cable.
  2. Properly drain the cooling system into an approved container.
  3. Remove all accessory drive belts or the serpentine belt.
  4. Remove the alternator and bracket. For details, please refer to Section 2 of this manual.
  5. Unscrew the water pump pulley mounting bolts and then pull off the pulley.
  6. Unfasten the mounting bolts, then remove the water pump.
  7. Using a putty knife, clean the gasket mounting surfaces. Fig. 1: Location and mounting of the water pump on the 2.2L engine 87953068.gif
    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
    Fig. 3: Remove the pulley from the water pump 91143p90.jpg
    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
    Fig. 6: Thoroughly clean the gasket mating surfaces on the engine block as well as . . . 91143p87.jpg
    Fig. 7: . . . the water pump (if it is being reused) 91143p89.jpg
    Fig. 8: Always use a quality new gasket like this one from Fel-Pro® 91143p88.jpg
    To install:
  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.
  13. Connect the negative battery cable, then start the engine and check for leaks.
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.

Sep 13, 2010 | Pontiac Sunfire Cars & Trucks

1 Answer

I have a 1992 Isuzu Bighorn model3.1D. The head has just been reconditioned, 4 cylinders honed, new rings, pistons and crankshaft seals were installed. An old radiator was put in place. After a week of...


The best check is fill the radiator with water when the engine is running and see if the water blows out the top of the rad. it it does then you have cylinder head problem's if not a new rad. will sort it. Cheers

Oct 20, 2009 | 1992 Isuzu Trooper

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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