GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 Engine 🢒 Engine Cooling 🢒 Water Pump Replacement

Water Pump Replacement LE5

Special Tools

    • J 25025-5 Dial Indicator Mounting Post
    • J 43651 Water Pump Holding Tool

Removal Procedure

    Object Number: 896331 Size: SH
  1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.
  2. Remove the coolant heater. Refer to Coolant Heater Replacement.
  3. Remove the water pump access plate from the front cover.

    4. Object Number: 789912 Size: SH

    Note: The water pump holding tool supports the sprocket and chain during water pump service. The tool must be used or the balance shaft must be re-timed.

  4. Install the J 43651 into position.
  5. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  6. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  7. Remove the 3 inner water pump sprocket to water pump bolts through the holes in the water pump holding tool.

    8. Object Number: 951420 Size: SH

    Note: Be sure to remove both water pump bolts from the front of the engine block.

  8. Remove the 2 water pump bolts.

    9. Object Number: 1578334 Size: SH
  9. Remove the rear 2 water pump bolts.

    10. Object Number: 951638 Size: SH
  10. Remove the engine wiring harness clip nut from the water pump stud.
  11. Remove the engine wiring harness clip from the stud.
  12. Remove the water pump.

Installation Procedure

    Object Number: 964352 Size: SH
  1. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the water pump drain plug and tighten to 20 N·m (15 lb ft).

    3. Object Number: 951802 Size: SH

    Note: A guide pin can be created to aid in water pump alignment. Use a M6 m x 6 mm stud. Thread the pin into the water pump sprocket.

  3. Using the J 25025-5 , or a guide pin align the pin with the water pump holding tool.
  4. Position the water pump against the engine block and hand tighten the water pump bolts.
  5. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten the water pump bolts to 25 N·m (18 lb ft).
  6. Tighten the water pump sprocket bolts last to 10 N·m (89 lb in).

    7. Object Number: 789912 Size: SH
  7. Remove the J 43651 .
  8. Install the coolant heater. Refer to Coolant Heater Replacement.

    9. Object Number: 896331 Size: SH
  9. Install the water pump access plate and bolts and tighten to 10 N·m (89 lb in).
  10. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.

Water Pump Replacement LY7

Special Tools

EN 46104 Water Pump Pulley Holding Tool

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the drive belt. Refer to Drive Belt Replacement.

    3. Object Number: 1412158 Size: SH
  3. Use the EN 46104 in order to retain the water pump pulley.

    4. Object Number: 1412160 Size: SH
  4. Remove the water pump pulley bolts.
  5. Remove the water pump pulley.

    6. Object Number: 1412162 Size: SH
  6. Remove the water pump bolts.
  7. Remove the water pump.
  8. Remove and DISCARD the water pump seal.
  9. Carefully clean the water pump sealing surfaces.

Installation Procedure

    Object Number: 1412162 Size: SH
  1. Install a NEW water pump seal.
  2. Install the water pump.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the water pump bolts and tighten to 10 N·m (89 lb in).

    4. Object Number: 1412160 Size: SH
  4. Install the water pump pulley and the water pump pulley bolts.

    5. Object Number: 1412158 Size: SH
  5. Use the EN 46104 in order to retain the water pump pulley.
  6. Install the water pump pulley bolts and tighten to 10 N·m (89 lb in).
  7. Install the drive belt. Refer to Drive Belt Replacement.
  8. Fill the cooling system. Refer to Cooling System Draining and Filling.

Water Pump Replacement LAT

Special Tools

J 43651 Water Pump Holding Tool

Removal Procedure

    Object Number: 1820842 Size: SH
  1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.
  2. Remove the engine splash shield. Refer to Engine Splash Shield Replacement - Right Side.
  3. Remove the water pump access plate from the front cover.

    4. Object Number: 964352 Size: SH

    Note: A drain plug has been provided at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump.

  4. Drain the coolant from the water pump using the plug at the bottom of the pump.

    5. Object Number: 1820843 Size: SH

    Note: The water pump holding tool supports the sprocket and chain during water pump service. The tool must be used or the balance shaft must be re-timed.

  5. Install the J 43651 (1) into position.
  6. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  7. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  8. Remove the 3 inner water pump sprocket to water pump blots.

    9. Object Number: 951420 Size: SH

    Note: Be sure to remove both water pump bolts from the front of the engine block.

  9. Remove the 2 water pump bolts.

    10. Object Number: 1578334 Size: SH
  10. Remove the rear 2 water pump bolts.

    11. Object Number: 951638 Size: SH
  11. Remove the water pump.
  12. Remove and discard the water pump O-ring seal.

Installation Procedure

    Object Number: 951802 Size: SH

    Note: Prior to installing the water pump, read the entire procedure. This will help avoid balance shaft chain re-timing and ensure proper sealing.

  1. Install a NEW water pump O-ring seal.

    2. Note: A guide pin can be created to aid in water pump alignment. Use a M6 m x 6 mm stud. Thread the pin into the water pump sprocket.

  2. Using the guide pin, align the pin with the water pump holding tool.
  3. Position the water pump against the engine block and hand tighten the water pump bolts.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten the water pump bolts to 25 N·m (18 lb ft).
  5. Tighten the water pump sprocket bolts last to 10 N·m (89 lb in).

    6. Object Number: 1820843 Size: SH
  6. Remove the J 43651 (1).

    7. Object Number: 1820842 Size: SH
  7. Install the water pump access plate and bolts. Tighten the bolts to 10 N·m (89 lb in).
  8. Install the engine splash shield. Refer to Engine Splash Shield Replacement - Right Side.
  9. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.

Water Pump Replacement LZ4

Removal Procedure

    Object Number: 1557687 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Loosen the water pump pulley bolts.
  3. Remove the drive belt. Refer to Drive Belt Replacement.
  4. Remove the water pump pulley bolts and pulley.

    5. Object Number: 1557689 Size: SH
  5. Remove the water pump bolts.
  6. Remove the water pump and gasket.
  7. Clean the water pump mating surfaces.

Installation Procedure

    Object Number: 1557689 Size: SH
  1. Position a NEW water pump gasket and the water pump to the engine front cover.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the water pump bolts and tighten to 25 N·m (18 lb ft).

    3. Object Number: 1557687 Size: SH
  3. Install the water pump pulley and bolts.
  4. Install the drive belt. Refer to Drive Belt Replacement.
  5. Tighten the water pump pulley bolts to 25 N·m (18 lb ft).
  6. Fill the cooling system. Refer to Cooling System Draining and Filling.
  7. Inspect for leaks.