Alero, Grand Am 1999-2005

Removal & Installation

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2.2L Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Exhaust manifold, if equipped with n automatic transaxle
     
    Right front wheel
     
    Splash shield
     
    Water pump sprocket access plate from the timing cover

    Click image to see an enlarged view

    Fig. Remove the water pump sprocket access plate from the timing cover -2.2L engine

     

  8.  
  9. Attach Water Pump Sprocket Holding Tool J 43651to the sprocket using the access plate bolts to secure the tool to the engine front cover.

    Sprocket to water pump bolts
     
    Engine block to water pump bolt
     
    Engine front cover to water pump bolt
     
    Thermostat housing to water pump feed pipe
     
    2 water pump to engine block bolts
     
    Water pump

    Click image to see an enlarged view

    Fig. Water pump mounting-2.2L engine

     

  10.  

To install:

  1. Use a threaded stud in the water pump hub to align the hub to the water pump sprocket.

    Water pump and bolts
     
    Thermostat housing to water pump feed pipe
     
    Engine front cover bolt and engine block to water pump bolt. Tighten the bolts to 15 ft. lbs. (20 Nm)
     
    2 of the water pump sprocket to water pump bolts
     

  2.  
  3. Remove the threaded stud.

    Last water pump sprocket to water pump bolt and tighten the sprocket bolts to 89 inch lbs. (10 Nm).
     

  4.  
  5. Remove the tool.

    Water pump sprocket access plate to the timing cover and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Splash shield
     
    Right front wheel
     
    Exhaust manifold, if removed
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  

2.4L Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    WARNING
    Do not rotate the flex coupling more than 4 degrees or damage may occur.



    Oxygen Sensor (O 2 S) electrical connector
     
    Exhaust manifold heat shield
     
    Coolant inlet housing bolt through the exhaust manifold
     
    Exhaust manifold brace-to-manifold bolt
     
    Manifold-to-exhaust pipe studs
     
    Coolant inlet housing-to-water pump cover bolt
     
    Exhaust pipe from the exhaust manifold by pulling it downward
     



    Coolant inlet pipe from the oil pan
     
    Brake vacuum pipe from the camshaft housing
     
    Exhaust manifold from the cylinder head
     
    Heater hose from the heater outlet pipe
     
    Timing chain cover and tensioner
     
    Water pump cover-to-engine bolts
     
    3 water pump-to-timing chain housing nuts
     
    Water pump and cover assembly
     
    Water pump cover from the pump

    Click image to see an enlarged view

    Fig. Exploded view of the water pump mounting-2.4L engine

     

  8.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket to the cover and tighten the bolts finger-tight
     
    Water pump cover-to-engine bolts and tighten finger-tight
     
    Water pump-to-timing chain housing nuts and tighten finger-tight
     
    Coolant inlet pipe into the water pump cover and tighten the bolts finger-tight
     

  2.  
  3. With all gaps closed, torque the bolts, in the following sequence, to the proper values:


    1. Pump assembly-to-chain housing nuts to 19 ft. lbs. (26 Nm).
    2.  
    3. Pump cover-to-pump assembly to 124 inch lbs. (14 Nm).
    4.  
    5. Water pump cover-to-engine bolts to 19 ft. lbs. (26 Nm).
    6.  
    7. Coolant inlet pipe assembly-to-water pump cover bolts to 124 inch lbs. (14 Nm).
    8.  

  4.  
  5. Install or connect the following:

    Exhaust manifold to the cylinder head. Torque the nuts to 11 ft. lbs. (15 Nm).
     
    Brake vacuum pipe to the camshaft housing
     
    Coolant inlet pipe to the oil pan. Torque the nuts to 19 ft. lbs. (25 Nm).
     
    Timing chain tensioner. Torque the bolts to 89 inch lbs. (10 Nm.).
     
    Front cover. Torque the bolts to 106 inch lbs. (12 Nm).
     
    Exhaust pipe to the manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Exhaust manifold brace to the manifold. Torque the bolt to 41 ft. lbs. (56 Nm) and the nuts to 19 ft. lbs. (26 Nm).
     
    Exhaust manifold to the exhaust pipe. Torque the nuts to 26 ft. lbs. (35 Nm).
     
    Heater hose to the heater pipe
     
    Exhaust manifold heat shield. Torque the bolts to 124 inch lbs. (14 Nm).
     
    O 2 S electrical connector
     
    Negative battery cable
     

  6.  
  7. Refill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

3.1L & 3.4L Engines



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Accessory drive belt
     
    Water pump pulley
     
    Water pump
     

  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the water pump mounting-3.1L & 3.4L engines

  1. Install or connect the following:

    Water pump with a new gasket. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Water pump pulley. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  
  3. Refill and bleed the cooling system.
  4.  
  5. Test run the engine and check for leaks.
  6.  

 
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