GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Bonneville 🢒 Engine 🢒 Engine Mechanical - 4.6L 🢒 Water Crossover Assemble

Tools Required

J 38816-A Water Pump Remover/Installer


    Object Number: 637030 Size: SH

    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.

  1. Install the water pump and seal using the following procedure:
    2. 1.1. Install the new water pump seal.
    1.2. Place the water pump into the water crossover. Ensure the water pump tabs are correctly indexing the water crossover tabs.
    1.3. Index the J 38816-A socket into the water pump.
    1.4. Align the J 38816-A support plate on the water crossover.
    1.5. Install the J 38816-A support plate on the water crossover using the water pump cover bolts.
    1.6. Tighten the water pump in the water crossover by turning the J 38816-A socket counter-clockwise.

    Tighten
    Tighten the J 38816-A socket to 100 N·m (74 lb ft).

    1.7. Remove the J 38816-A support plate from the water crossover.
    1.8. Remove the J 38816-A socket.

    Object Number: 522696 Size: SH
  2. Install the water pump cover gasket.
  3. Install the water outlet and thermostat.
  4. Install the water outlet bolts.

    5. Tighten
    Tighten the water outlet bolts to 10 N·m (89 lb in).


    Object Number: 522698 Size: SH
  5. Install the water pump cover.

    6. Object Number: 682832 Size: SH

    Important: Ensure the bolt is installed in the lower inboard position (1) and the studs are installed in the remaining positions (2).

  6. Install the water pump cover bolt and studs.

    7. Tighten
    Tighten the water pump cover bolt and studs to 10 N·m (89 lb in).


    Object Number: 522699 Size: SH
  7. Install the MAP sensor.

    8. Object Number: 522700 Size: SH
  8. Install the accelerator control cable bracket.
  9. Install the accelerator control cable bracket bolts.

    10. Tighten
    Tighten the accelerator control cable bracket bolts to 9 N·m (80 lb in).


    Object Number: 522701 Size: SH

    Important: Do not use any type of sealant between the NEW plenum duct and the water crossover.

  10. Install the throttle body and the NEW plenum duct.
  11. Install the throttle body bolts.

    12. Tighten
    Tighten the throttle body bolts to 10 N·m (89 lb in).


    Object Number: 522703 Size: SH
  12. Install the NEW EGR gasket.
  13. Install the EGR valve.
  14. Install the EGR valve bolts.

    15. Tighten
    Tighten the EGR valve bolts to 24 N·m (17 lb ft).


    Object Number: 522705 Size: SH
  15. Install the EGR bracket shield.
  16. Install the EGR bracket shield nut.

    17. Tighten
    Tighten the EGR bracket shield nut to 10 N·m (89 lb in).


    Object Number: 522706 Size: SH
  17. Install the EVAP emission canister purge valve.
  18. Install the EVAP emission canister purge valve bolts.

    19. Tighten
    Tighten the EVAP emission canister purge valve bolts to 10 N·m (89 lb in).


    Object Number: 522707 Size: SH
  19. Install the rear lift bracket.
  20. Install the rear lift bracket bolt.

    21. Tighten
    Tighten the rear lift bracket bolt to 24 N·m (17 lb ft).

  21. Install the engine coolant outlet fitting.

    22. Tighten
    Tighten the engine coolant outlet fitting to 47 N·m (35 lb ft).


    Object Number: 639830 Size: SH
  22. Install the heater inlet pipe fitting.

    23. Tighten
    Tighten the heater inlet pipe fitting to 40 N·m (30 lb ft).