Service Information Regarding Elimination of Front Auxiliary Water Pump and Instructions to Install Elbow in Place of Pump

This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-01-38-007 (Section 01 - HVAC).

The auxiliary water pump is not needed for vehicles with V-6 engines. Therefore, any time an auxiliary water pump needs to be replaced, replace it with a modified heater inlet elbow. Refer to the service procedure in this bulletin to modify and install the elbow.

Auxiliary Pump Removal

1. Drain coolant. (Refer to the proper draining procedure in SI or the appropriate Saturn L-Series Service Manual.)



2. Disconnect both cooling fan electrical connectors. Move the wiring harnesses and connectors out of the way.



3. Remove the radiator upper mount brackets. This will allow more access to the auxiliary water pump.
4. Disconnect the auxiliary water pump electrical connector and remove harness from clip.



5. Remove auxiliary water pump inlet hose to auxiliary water pump, leaving clamp on hose.
6. Remove auxiliary water pump outlet hose to auxiliary water pump, leaving clamp on hose.



7. Remove auxiliary water pump to fan shroud by lifting clip tabs with screwdriver and sliding clips outward.
8. Remove pump and discard.



9. Using an appropriate metal cutting tool, remove the bracket from the heater inlet elbow, P/N 22702079. Discard bracket.
10. Remove any sharp edges from the cut surface using a file.
11. Apply rust inhibiting paint or primer to the cut surface of the elbow. (Refer to SI or the appropriate Saturn L-Series Collision Repair Service Manual.)
12. Install the auxiliary water pump inlet hose to one end of the elbow, making sure to orient the elbow so the outlet hose can be installed at the other end of the elbow.
13. Secure inlet hose to elbow using hose clamp.
14. Install the auxiliary water pump outlet hose to the other end of the elbow.
15. Secure outlet hose to elbow using hose clamp.
16. Using a wire tie strap, secure the elbow to the fan shroud assembly making sure to not interfere with the cooling fan.



17. Cut connector for auxiliary water pump from engine harness at the connector.
18. Remove tape on the auxiliary coolant pump wires.



19. Remove insulation from end of cut wires.

Recommended strip length is 9.5 mm (3/8 in.).




20. Install salmon splice sleeve, P/N 12089189, by positioning stripped end into sleeve until wire hits stop in center of the splice sleeve.
21. Hand crimp sleeve using the approved crimping tool found in Terminal Repair Kit J-44020. Gently tug on wires to make sure they are secure before applying heat to them.




Caution: Do not use match or open flame to apply heat to seal. Use of a match or open flame may cause scorching or worse, the seal could start to combust or burn.

22. Apply heat using the heat gun or some other device. Heat to 175° C (347° F) until glue flows around edges of sleeve.



23. While the sleeve is still hot, use a pair of pliers and pinch the open end of the sleeve together. Hold together for about 10 seconds.
24. Repeat steps 18-21 for the second wire.
25. Tape wires together and install into conduit.
26. Wrap end of conduit with electrical tape.



27. Install the radiator upper mount brackets.



28. Connect both cooling fan electrical connectors.
29. Fill cooling system. (Refer to the proper coolant filling procedure in SI or the appropriate Saturn L-Series (L81) Service Manual.)
30. Use fresh water to rinse away any coolant that was spilled during service.

*Can be ordered through Delphi-Packard by calling 1-800-PACKARD.

**Also available in the Saturn Special Tool Catalog found with J 44020 Terminal Repair Kit.

For vehicles repaired under warranty, use: