Water Pump Replacement 2.2L (L61)

Tools Required

J 43651 Water Pump Holding Tool

1. Drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the thermostat housing pipe-to-cylinder bolt near the front of the engine.



3. Remove the exhaust manifold heat shield and bolts.



4. Remove the water pump access plate from the front cover.
5. Remove the right hand wheel nuts and wheel assembly.
6. Remove the right hand inner push-pins and splash shield.




Important: 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.

7. Drain the coolant from the plug at the bottom of the water pump.
8. Disconnect the engine coolant temperature sensor electrical connector.



9. Remove the thermostat housing bolts.
10. Move the thermostat housing toward the left hand side of the vehicle while twisting the water feed pipe from the rear of the water pump assembly. Leave the coolant hoses and thermostat housing cover connected.
11. Remove the water feed pipe.
12. Discard the water pipe seals.




Important: 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.

13. Install the J 43651 into position.
14. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
15. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
16. Remove the 3 inner water pump sprocket to water pump blots.




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

17. Remove the 2 water pump assembly bolts.



18. Remove the rear 2 water pump assembly bolts.
19. Remove the water pump assembly and water pump O-seal.

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

1. Install a new water pump assembly seal.




Important: 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 assembly against the engine block and hand tighten the water pump bolts.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the third bolt.

Tighten
Tighten the water pump bolts to 25 N·m (18 lb ft).

5. Tighten the water pump bolts.

Tighten
Tighten the water pump sprocket-to-water pump bolts to 10 N·m (89 lb in).

6. Remove the J 43651 .
7. Install the water pump access plate and bolts.

Tighten
Tighten the water pump access bolts-to-front cover to 10 N·m (89 lb in).

Important: The water feed pipe seals can be lightly lubricated with silicone gel to aid in assembly.

8. Install a new O-ring seal on the water feed pipe.



9. Install the thermostat housing to block seal onto the thermostat housing, if damaged.
10. Install the water feed pipe into the water pump assembly.
11. Align the water feed pipe to the thermostat housing assembly.
12. Seat the water feed O-ring seal by pushing and twisting toward the water pump. Take care not to tear or damage the O-ring.
13. The water feed pipe has a locating tab to assure proper alignment.
14. Position the thermostat housing against the engine. Be sure that the thermostat housing pipe is properly positioned against the support bracket near the front of the engine.
15. Install the thermostat housing to block bolts.

Tighten
Tighten the thermostat housing-to-block bolts to 10 N·m (89 lb in).




16. Connect the electrical connector to coolant temperature sensor.
17. Install the right hand inner splash shield and push pins.
18. Install the right hand tire assembly and wheel nuts.

Tighten
Tighten the wheel nuts to 125 N·m (92 lb ft).

19. Lower the vehicle.
20. Install the thermostat pipe bracket to cylinder head bolt.

Tighten
Tighten the thermostat pipe bracket-to-cylinder head bolt to 8 N·m (71 lb in).




21. Install the exhaust manifold heat shield.
22. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the exhaust manifold heat shield bolts to 23 N·m (17 lb ft).

Important: The vehicle must be level when filling the cooling system.

23. Verify the drain valves at the radiator and water pump are closed.
24. Fill the engine coolant. Refer to Cooling System Draining and Filling .
25. Verify the repair and inspect for any leaks.

Water Pump Replacement 3.5L (L66)

1. Drain the coolant. Refer to Cooling System Draining and Filling.
2. Remove the timing belt. Refer to Timing Belt Replacement.




Important: 

•	When a vehicle is diagnosed to have coolant leaking inside the timing belt cover, a visual inspection of the timing belt should be completed. If there is any indication that coolant has leaked onto the timing belt (i.e. wetness, staining, etc.), the timing belt should be replaced.

•	When replacing the water pump, coolant will be spilled onto the timing belt. Replacement of the timing belt due to coolant spillage on the belt is not necessary.

3. Remove the water pump assembly bolts.
4. Remove the water pump and O-ring.

1. Clean and block at the water pump mating surface.
2. Install a new water pump O-ring to the water pump.
3. Install the water pump assembly.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the water pump bolts.

Tighten
Tighten the water pump bolts to 12 N·m (106 lb in).

5. Install the timing belt. Refer to Timing Belt Replacement.
6. Fill the coolant system. Refer to Cooling System Draining and Filling.