Water pump hose/pipe

If you have the V6 (2.5L) engine, be advised: it's a wearing task. Just getting to the radiator drain plug can be a problem without a 3/8 inch drive ratchet, a 3 inch extension, a universal joint. and a 19 mm socket. The drain plug is on the passenger side of the radiator on the engine side. The 19mm socket will fit over the drain plug to turn it open.
The coolant plumbing on this engine is the craziest I have ever seen. The thermostat is on the rear face of the engine (where the radiator hoses connect), but not on the upper hose where it connects to the upright pipe with the radiator cap on it, it is on the lower hose connection. Pull that hose off the housing, and remove the three bolts holding the thermostat housing to the engine. It will help if you first remove the big air inlet hose from the air filter housing to the throttle body. I wouldn't even bother with the thermostat till you have found the leak. Is any coolant leaking from the front of the engine, dripping off the bottom behind the crank pulley? That would be a water pump problem or SEAL, an o-ring on the back of the water pump. Now get on the driver's side and look around on the rear of engine nearest the firewall where engine and transaxle mate. Look down there for signs of coolant coming from rear of engine and running down onto the transaxle case. There is a metal pipe laying in the valley below the lower intake manifold, connecting the water pump at the front and the rear housing where the radiator hoses and heater hoses connect. This metal pipe uses an o-ring for a seal into the water pump, and the same size o-ring to connect to the rear housing. If one of those o-rings is leaking, you have a big problem getting to it.. I took the rear housing off once (never again!), Now I'm taking the water pump off to fix a leak. The water pump is run by the timing belt, so the front of engine needs to be stripped down, and the timing belt removed to take off the water pump. That metal pipe is held in place by a bracket with one bolt on the rear of engine; it may require taking the lower intake off (again) to get to both of those pesky o-rings. I hope you don't have the same problem, and if you have the 4 cylinder engine, the thermostat is a snap to replace, plus you don't have that crazy plumbing problem.

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.

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

its not normal. the water pump will leak in front, not back. There is a pipe and hose down in the VEE that can leak. If the pipe is bad, you will need to remove the pump to replace it. The intake manifold will need to come off, to replace the pipe/ hose. the hose connects a pipe behind the water pump to a pipe at the rear of the block to a heater hose.

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.

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.

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.
    

Make sure it's cool, pop the radiator cap, Remove the shield on the passenger side between the tire and front of engine. Relieve the tension on the serp belt,draw yourself a diagram of the pulleys and belt routing in case the sticker is gone on the strut tower, remove the serp belt. Take the bolts out of the pulley on the front of the water pump (3). Remove the lower radiator hose at the front cover to drain the coolant. Remove the 6 mm bolts holding the water pump to the front cover housing. tap on the pump with a rubber hammer. Install a new gasket on the new pump, and a weap hole diverter in the pump (round black about hte size of a quarter), use old one if there's no new one. Install pupm and tighten bolts snug with a 1/4" ratchet. Install pulley and 3 bolts. Install belt, top off radiator with 50/50 mix green coolant. start engine and run to operating temperature,make sure the belt is seated in all of the pulleys and is running true, radiator fans should come on. Shut engine down and let cool overnight. Check level in radiator and overflow bottle, top off as necessary.

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.
   

Yes, there is a "bypass outlet" coolant hose that connects from the water pump inlet pipe (metal pipe that runs from back of water pump along engine block to lower radiator hose) to the intake manifold.

I am not sure about the "black box" - not enough detail.