Auxiliary Water Pump Replacement 2.4L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Disconnect the negative battery cable.
2. Drain the coolant. Recover the coolant. Refer to Cooling System Draining and Filling .
3. Disconnect the oxygen sensor (O2S) connector.
4. Remove the upper exhaust manifold heat shield.
5. Disconnect the heater hose quick connect from the heater outlet pipe.
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Remove the exhaust manifold brace to manifold bolt.
8. Remove the manifold to exhaust pipe bolts.
9. Remove the heater outlet pipe bracket to transmission bolt.
10. Break loose the manifold to exhaust pipe bolts.



11. Remove the radiator outlet pipe assembly to coolant pump cover (2) bolts (1).

Notice: Do not rotate the flex coupling more than 4 degrees. Damage to the flex coupling may occur.

12. Remove the exhaust pipe from the exhaust manifold. Pull down and back on the exhaust manifold pipe in order to disengage the pipe from the exhaust manifold.



13. Remove the radiator outlet pipe (1) from the oil pan (2) and transaxle.

•	With a manual transaxle, remove the exhaust manifold brace.

•	Keep the lower radiator hose attached. Pull down on the radiator outlet pipe in order to disengage the pipe from the coolant pump. Leave the radiator outlet pipe hanging.

14. Lower the vehicle.
15. Remove the following parts in order:

15.1.

The brake vacuum pipe from the cam housing

15.2.

The exhaust manifold to cylinder head retaining nuts

15.3.

The exhaust manifold

15.4.

The seals and gaskets of the exhaust manifold.

16. Remove the front timing chain cover. Refer to Timing Chain Housing Replacement in Engine Mechanical - 2.4L.
17. Remove the timing chain tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L.



18. Remove the coolant pump cover to cylinder block bolts.



19. Remove the coolant pump to timing chain housing nuts.
20. Remove the coolant pump (1) and cover assembly.
21. Remove the coolant pump cover to coolant pump assembly bolts (4).
22. Clean all sealing surfaces.

Important: Before you install the coolant pump, read the entire procedure. Pay special attention to the tightening sequences in order to avoid part damage and to provide proper sealing.




1. Install the coolant pump cover to the coolant pump assembly (3).
2. Install the coolant pump cover to coolant pump bolts. Hand tighten the bolts.
3. Install the coolant pump cover to block bolts. Hand tighten the bolts.



4. Install the coolant pump to timing chain housing (1) nuts. Hand tighten the nuts.



5. Lubricate the o-ring on the radiator outlet pipe with an antifreeze solution.

5.1.	Slide the outlet pipe into the coolant pump cover.

5.2.	Install the bolts. Hand tighten the bolts.




6. Tighten the coolant pump assembly to timing chain housing nuts.
7. Tighten the coolant pump cover to pump assembly.
8. Tighten the coolant pump cover to engine block. Tighten the bottom bolt first.
9. Tighten the radiator outlet pipe assembly to coolant pump cover.
10. Using new gaskets, install the exhaust manifold.
11. Install the exhaust manifold to cylinder head retaining nuts.
12. Connect the brake vacuum pipe to the cam housing.
13. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
14. Index the exhaust manifold bolts into the exhaust pipe flange.
15. Install the exhaust pipe to the exhaust manifold.
16. Install the heater outlet pipe bracket to the transmission.
17. Turn both bolts in evenly in order to avoid cocking the exhaust pipe and binding the bolts. Turn in the bolts until the bolts are fully seated.



18. Install the radiator outlet pipe to the oil pan (2). With a manual transaxle, install the exhaust manifold brace.
19. Install the timing chain tensioner.
20. Install the timing chain cover.
21. Lower the vehicle.
22. Install the exhaust manifold brace to manifold bolt.
23. Tighten the manifold to exhaust pipe nuts.
24. Connect the heater hose to the heater outlet pipe.
25. Install the upper heat shield to the manifold.
26. Connect the oxygen sensor (O2S) connector.
27. Fill the radiator with coolant until the coolant level reaches the heater hose coolant outlet. Then install the hose (this action assists in a complete cylinder block fill). Continue the filling procedure. Refer to Cooling System Draining and Filling .
28. Connect the negative battery cable.
29. Inspect for leaks.

Auxiliary Water Pump Replacement 3.1L

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Drain and recover the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the drive belt.
3. Remove the coolant pump pulley bolts.
4. Remove the coolant pump pulley.



5. Remove the coolant pump attaching bolts.
6. Remove the coolant pump.
7. Clean the coolant pump and the sealing surfaces.

1. Using a new gasket, install the coolant pump.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolts.

Tighten
Tighten the coolant pump bolts to 10 N·m (89 lb in).

3. Install the coolant pump pulley.
4. Install the drive belt.
5. Refill the cooling system. Refer to Cooling System Draining and Filling
6. Inspect for leaks.