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How do u install a lower water pipe on a JD 720?

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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

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

How to replace a waterpump on a 2001 olds alero 2.4 cam


Water pump is driven by timing chain idler and is mounted on the rear of the timing chain housing. Disconnect the neg. battery cable. Drain cooling system. Disconnect oxygen sensor connector.
Remove upper exhaust manifould heat sheild. Remove exhaust manifold brace. Remove lower exhaust manifold heat sheild. Loosen manifold to exhaust manifold spring loaded nuts. Remove radiator outlet pipe to water pump coverbolts. Disconnect exhaust pipe from manifold.
Pull down on the exhaust pipe to disconnect it from exhaust manifold bolts. Disconnect outlet pipe from oil pan and transaxle. If equipped with manual tranaxle, remove exhaust maifold brace. Leave lower radiator hose attached and pull down on radiator out look pipe to disengauge from water pump. Leave outlet pipe hanging.
Lower vehicle. Remove exhaustmanifold to cylinder head nuts. Remove exhaust manifold to cylinder head nuts. Remove manifould. Remove timing chain front cover. Remove timing chain tensioner. Remove bolts bolts securing water pump cover to cylinder block. Remove water pump to timing chain housing nuts. Remove water pump attaching nuts. Remove water pump and cover assembly. Separate componets as necessary.
WHEN INSTALLING WATER PUMP MAKE SURE YOU FOLLOW THE TIGHTENING SEQUENCES THAT AFFECT SEALING. My frist one I messed up and broke the pump so becarful.
Installation
If cover was separated from body during removal, join this componets with a new gasket and hand tighten bolts. Apply bearing grease to splines of water pump drive. Set body and assemble into position.
Install and hand tighten bolts securing cover to cylinder block. Install and hand tighten bolts securing cover to cylinder block. Installand hand tighten nuts securing body to timing chain housing. Lubracate outlet pipe "O" ring with antifreeze. (I use RTV) Connect outlet pipe. Install and hand tighten bolts. Tighten bolts and nuts to specification in the following sequence. I'll ad the torque spec. at the end but this is where if you tighten out of order something will break.
pump assembly to timing chain housing nuts.
pump cover to pump body bolts
pump cover to cylinder block bolts (Bottom Bolt First)
outlet pipe to cover bolts
To complete installation reverse removel procedure.
Torque specs are 19 in. or 26mm all except water pump cover bolts which are 124 in or 14Nm
I never torque the bolts just make sure there done in the right order.

Oct 19, 2010 | Oldsmobile Alero Cars & Trucks

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

2 Answers

Where is the thermostat on a 2.2l ohc engine?


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: chevy_cav_02-04_tstat.gif

    • Thermostat housing to water pump feed pipe bolts. chevy_cav_02-04_feedpipe.gif

    • 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. cavman.gif

    cavtstat.gif

  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.
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Sep 09, 2010 | 2003 Pontiac Sunfire

1 Answer

How to replace timing belt on a 1992 pontiac sunbird


1989–92 VEHICLES
  1. Disconnect the negative battery cable.
  2. Remove the serpentine belt and timing belt cover.
  3. Loosen the water pump bolts and release tension with tool J–33039 or equivalent.
  4. Raise and support the vehicle safely.
  5. Remove the crankshaft pulley.
  6. Carefully lower the vehicle, then remove the timing belt. Fig. 11: Exploded view of the timing belt assembly — 1989–92 OHC engines 87953118.gif
    To install:
  7. Turn the crankshaft and the camshaft gears clockwise to align the timing marks on the gears with the timing marks on the rear cover.
  8. Install the timing belt, making sure the portion between the camshaft gear and crankcase gear is in tension.
  9. Using tool J–33039 or equivalent, turn the water pump eccentric clockwise until the tensioner contacts the high torque stop. Tighten the water pump screws slightly.
  10. Turn the engine by the crankshaft gear bolt 720°to fully seat the belt into the gear teeth.
  11. Turn the water pump eccentric counterclockwise until the hole in the tensioner arm is aligned with the hole in the base.
  12. Tighten the water pump screws to 18 ft. lbs. (24 Nm), while checking that the tensioner holes remain as adjusted in the prior step.
  13. Install the crankshaft pulley, timing belt cover and the serpentine drive belt.
1993–94 VEHICLES
  1. Disconnect the negative battery cable, then partially drain and recover the cooling system.
  2. Remove the coolant recovery reservoir.
  3. If equipped, remove the A/C belt.
  4. Remove the serpentine belt.
  5. Disconnect the evaporative emission pipe assembly.
  6. Remove the crankshaft pulley assembly.
  7. As outlined earlier, remove the timing belt front cover.
  8. Align the marks on the crankshaft sprocket with the marks on the rear timing belt cover by rotating the crankshaft.
  9. Loosen the water pump retaining bolts, and release the tension with tool J 33039-A or equivalent.
  10. Carefully lower the vehicle, then remove the timing belt. Fig. 12: Timing belt installation and tightening specifications — 1993–94 2.0L OHC engines 87953119.gif
    To install:
  11. Turn the crankshaft and camshaft gears clockwise to align the timing marks on the gears with the timing marks on the rear cover.
  12. Install the timing belt, making sure that the portion between the camshaft gear and crankshaft gear is in tension.
  13. Using tool J 33039-A, or equivalent adjustment tool, turn the coolant pump eccentric clockwise until the tensioner arm contacts the high torque stop. Tighten the water pump screws slightly.
  14. Turn the engine by the crankshaft gear bolt 720°clockwise to fully seat the belt into the gear teeth.
  15. Turn the coolant pump eccentric counter clockwise until the hole in the tensioner arm is aligned with the hole in the base. This must be done with the engine at room temperature, approximately 68°F (20°C).
  16. Tighten the water pump screws while checking that the tensioner holes remain as adjusted as in step 15.
  17. As outlined earlier, install the timing belt cover.
  18. Install the crankshaft pulley.
  19. Connect the evaporative emission pipe assembly.
  20. Install the serpentine drive belt and the A/C belt (if equipped).
  21. Install the coolant recovery reservoir.
  22. Properly fill the cooling system, then connect the negative battery cable.
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Aug 11, 2010 | 1992 Pontiac Sunbird

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

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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