2005 isuzu leaking water at exhaust connection

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.

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.

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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
    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
   
   
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.

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
    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.

Thermostat Removal & Installation 2.2L Engine To Remove:

1. Remove the exhaust manifold. If equipped with an automatic transmission.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   • Thermostat housing to water pump feed pipe bolts.
     
     
   • Thermostat housing to water pump feed pipe.
   • Thermostat.

To Install:

1. Install or connect the following:
   • Thermostat.
   • Thermostat housing to water pump feed pipe.
   • Thermostat housing to water pump feed pipe bolt.
     1. Tighten bolt to 89 in lbs (10 Nm).
   • Exhaust manifold if equipped with an automatic transmission.
2. Fill the cooling system.

2.4L Engine To Remove:
Thermostat assembly 2.4L

1. Drain the cooling system.
2. Remove the exhaust manifold heat shield.
3. Remove the coolant inlet housing mounting bolts through the exhaust manifold.
4. Raise and safely support the vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove wheel and tire assembly.
7. Remove the engine splash shield.
8. Remove the mounting bolts from the transaxle-to-engine block support. Remove the support.
9. Remove the coolant housing pipe.
10. Remove the thermostat.
11. Clean the mating surfaces.

To Install:

1. Install the thermostat.
2. Install the coolant housing pipe.
3. Install and secure the transaxle support-to-engine block mounting bolts.
4. Install the engine splash shield.
5. Install the wheel and tire assembly.
6. Install the coolant inlet housing stud to the oil pan.
   • Tighten to 19 ft lb (26 Nm).
7. Lower the vehicle.
8. Install the coolant inlet housing bolts through the exhaust manifold.
   • Tighten the coolant inlet housing bolts to 10 ft lb (14 Nm).
9. Install the exhaust manifold heat shield.
10. Fill the cooling system.
11. Inspect the system for leaks.

3.4L Engine To Remove:

1. Drain the cooling system.
2. Remove the air cleaner.
3. Remove exhaust crossover pipe.
4. Disconnect the surge tank line fitting from the coolant outlet.
5. Remove the thermostat housing to intake manifold bolts.
6. Remove the thermostat housing outlet and thermostat.

To Install:

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts.
   • Tighten the thermostat housing bolts to 18 ft lb (25 Nm).
3. Install exhaust crossover pipe.
4. Connect the surge tank line fitting to the coolant outlet.
   • Tighten the fittings to 15 ft lb (21 Nm).
5. Install the air cleaner.
6. Fill the cooling system.
7. Inspect the system for leaks

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
   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
   Fig. 3: Remove the pulley from the water pump
   Fig. 4: The water pump is retained by four bolts, remove them and . . .
   Fig. 5: . . . remove the water pump from the engine
   Fig. 6: Thoroughly clean the gasket mating surfaces on the engine block as well as . . .
   Fig. 7: . . . the water pump (if it is being reused)
   Fig. 8: Always use a quality new gasket like this one from Fel-Pro®
   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
    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.

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.
   

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.
    

Removal & Installation 2.2L VIN 4 To Remove:

1. Drain the cooling system.
2. Remove the lower radiator hose from thermostat housing.
3. Remove the thermostat housing bolts and outlet.
4. Remove the thermostat.
5. Clean the mating surfaces.

To Install:

1. Install the thermostat.
2. Install the thermostat housing and bolts.
3. Install the coolant housing bolts. Tighten bolts to 14 Nm (10 ft. lbs.).
4. Install the lower radiator hose to thermostat housing.
5. Fill the cooling system.
6. Inspect for leaks.

2.2L VIN F To Remove:

1. Remove the exhaust manifold. If equipped with an automatic transmission.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   • Thermostat housing to water pump feed pipe bolts.
     
     
   • Thermostat housing to water pump feed pipe.
   • Thermostat.

To Install:

1. Install or connect the following:
   • Thermostat.
   • Thermostat housing to water pump feed pipe.
   • Thermostat housing to water pump feed pipe bolt. Tighten bolt to 10 Nm (18 in. lbs.).
   • Exhaust manifold. If equipped with an automatic transmission.
2. Fill the cooling system.

2.4L VIN T To Remove:

1. Drain the cooling system.
2. Remove the exhaust manifold heat shield bolts and shield.
   
   
   
   
3. Remove the coolant inlet housing bolts.
4. Lift vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove the wheel.
7. Remove the right engine splash shield.
8. Remove the transaxle-to-engine block brace bolts and brace.
9. Remove the radiator outlet pipe.
10. Remove the thermostat.
11. Clean the mating surfaces.

To Install:

1. Clean the mating surfaces.
2. Install the thermostat.
3. Install the radiator outlet pipe.
4. Install the transaxle-to-engine block brace and install bolts.
5. Install the right engine splash shield.
6. Install the wheel.
7. Lower the vehicle.
8. Install the exhaust manifold heat shield and bolt.
9. Tighten the exhaust manifold heat shield bolts to 14 Nm (10 ft. lbs.).
10. Fill the cooling system.
11. Inspect the system for leaks.

Alero, Grand Am 1999-2005 Thermostat - Removal & Installation 2.2L Engine

1. If equipped with an automatic transaxle, remove the exhaust manifold, as outlined in this section.
2. Drain the cooling system.
3. Remove the thermostat housing to water pump feed pipe bolts.
4. Remove the thermostat housing to water pump feed pipe.
   
   
   Fig. Thermostat mounting-2.2L engine
   
5. Remove the thermostat.

To install:

1. Install the thermostat.
2. Install the thermostat housing to water pump feed pipe.
3. Install the thermostat housing to water pump feed pipe bolt. Tighten the thermostat housing to water pump feed pipe bolt to 89 inch lbs. (10 Nm).
4. If equipped with an automatic transaxle, install the exhaust manifold, as outlined in this section.
5. Fill the cooling system.

3.1L Engines

1. Disconnect the negative battery cable.
2. Drain the cooling system to a level below the thermostat housing.
3. Remove the air cleaner assembly.
4. Disconnect the surge tank line from the thermostat housing.
5. Remove thermostat housing-to-intake manifold attaching bolt and nut, then remove the housing.
6. Remove the thermostat.

To install:

1. Clean all gasket surfaces completely.
2. Insert the thermostat in the intake manifold.
3. Attach the thermostat housing to the intake manifold.
4. Install the mounting bolt and nut. Tighten to 18 ft. lbs. (25 Nm).
5. Install the air cleaner assembly.
6. Connect the surge tank line to thermostat housing.
7. Refill the cooling system.
8. 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.
9. Install the radiator cap, making sure the arrows line up with the overflow tube.

3.4L Engine

1. Drain the cooling system.
2. Remove the air cleaner.
3. Remove exhaust crossover pipe.
4. Disconnect the surge tank line fitting from the coolant outlet.
5. Remove the thermostat housing to intake manifold bolts.
6. Remove the thermostat housing outlet and thermostat
7. Clean the mating surfaces.

To install:

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts. Tighten the thermostat housing bolts to 18 ft. lbs. (25 Nm).
3. Install exhaust crossover pipe.
4. Connect the surge tank line fitting to the coolant outlet. Tighten the fittings to 15 ft. lbs. (21 Nm).
5. Install the air cleaner.
6. Fill the cooling system.
7. Inspect the system for leaks.

Hope this help (remember comment and rated this).

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.

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.
   

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:
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.