CTS 2003-2005

Removal & Installation

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2.8L & 3.6L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the alternator and water pump drive belt.
  8.  
  9. Install Water Pump holding tool EN-46104 to retain the water pump pulley.
  10.  
  11. Remove or disconnect the following:

    Water pump pulley bolts
     
    Water pump pulley
     
    Water pump mounting bolts
     
    Water pump
     

  12.  

To install:

Click image to see an enlarged view

Fig. Using special tool EN-46104 to retain the pulley when installing water pump pulley bolts-2.8L and 3.6L

  1. Install or connect the following:

    Water pump with a NEW gasket. Tighten mounting bolts to 89 inch lbs. (10 Nm).
     
    Water pump pulley. Tighten pulley bolts to 106 inch lbs. (12 Nm).
     
    Drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.1L And 3.4L (VIN E) Engines



  1. Disconnect the negative battery cable.
  2.  
  3. Partially drain the cooling system into a suitable container.
  4.  
  5. Remove the drive belt guard.
  6.  
  7. Loosen the water pump pulley bolts before removing the drive belt. This should help keep the pulley from turning as the bolts are loosened.
  8.  
  9. Remove the drive belt. Please see Section 1.
  10.  
  11. Remove the water pump pulley bolts and remove the pulley.
  12.  
  13. Remove the water pump bolts and separate the pump from the engine front cover.
  14.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the water pump and front cover arrangement-3.1L and 3.4L (VIN E) engines

  1. Clean all parts well. Use care when scraping gasket material from the front cover and the pump. Do not gouge aluminum parts. Clean the bolt threads well. The torque specification is low and if the bolt threads are dirty, an accurate torque is not possible and leaks are likely to develop.
  2.  
  3. Using a new gasket, install the water pump to the front cover. Install the cleaned and lightly lubricated water pump bolts. Torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the water pump pulley and bolts and torque to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the remaining components in the reverse order of the removal process. When refilling the cooling system, use the proper mix of DEX-COOL® and water. Check for leaks.
  8.  

3.2L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake air resonator
     
    Water pump pulley bolts, loosen only
     
    Front timing belt cover
     
    Water pump pulley
     
    Water pump

    Click image to see an enlarged view

    Fig. Exploded view of the water pump mounting

     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new O-ring. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Water pump pulley
     
    Front timing belt cover
     
    Intake air resonator
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system through the reservoir tank.
    NOTE
    When refilling the cooling system, add 2 crushed engine coolant supplement sealant pellets (PN 3634621) into the coolant reservoir.

  4.  
  5. Start the vehicle and inspect the coolant systems for leaks.
  6.  

3.4L (VIN X) Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Partially drain the cooling system into a suitable container.
  4.  
  5. Remove the coolant recovery reservoir.
  6.  
  7. Remove the drive belt. Please see Section 1.
  8.  
  9. Remove the pulley bolts and separate the pulley from the water pump.
  10.  
  11. Remove the water pump bolts and remove the pump from the engine.
  12.  



Click image to see an enlarged view

Fig. Exploded view of the water pump mounting-3.4L (VIN X) engine

To install:

  1. Clean all parts well. Use care when scraping gasket material from the front cover and the pump. Do not gouge aluminum parts. Clean the bolt threads well. The torque specification is low and if the bolt threads are dirty, an accurate torque is not possible and leaks are likely to develop.
  2.  
  3. Using a new gasket, install the water pump to the front cover. Install the cleaned and lightly lubricated water pump bolts. Torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the water pump pulley and bolts and finger-tighten the bolts.
  6.  
  7. Install the drive belt, then torque the pulley bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the remaining components in the reverse order of the removal process. When refilling the cooling system, use the proper mix of DEX-COOL® and water. Check for leaks.
  10.  

3.5L Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Partially drain the cooling system into a suitable container.
  4.  
  5. Loosen the water pump pulley bolts before removing the drive belt. This should help keep the pulley from turning as the bolts are loosened.
  6.  
  7. Remove the drive belt. Please see Section 1.
  8.  
  9. Remove the idler pulley bolt and remove the idler pulley.
  10.  
  11. Remove the water pump pulley bolts and remove the pulley.
  12.  
  13. Remove the water pump bolts and separate the pump from the engine. Note that bolt lengths vary. There are long and short bolts. Use care to note the length of bolts as they are removed and the location from which they were removed so they can be returned to their proper locations. Discard the gasket.
  14.  



Click image to see an enlarged view

Fig. Water pump mounting and bolt locations-3.5L (VIN H) Engine

To install:

  1. Clean all parts well. Use care when scraping gasket material from the front cover and the pump. Do not gouge aluminum parts. Clean the bolt threads well. The torque specification is low and if the bolt threads are dirty, an accurate torque is not possible and leaks are likely to develop.
  2.  
  3. Using a new gasket, install the water pump to the front cover. Install the cleaned and lightly lubricated water pump bolts finger-tight, then torque to 124 inch lbs. (14 Nm).
  4.  
  5. Install the water pump pulley and bolts and finger-tighten the bolts.
  6.  
  7. Install the idler pulley and bolt. Tighten the idler pulley bolt to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the drive belt, then, with the drive belt holding the pulley from turning, torque the water pump pulley bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the remaining components in the reverse order of the removal process. When refilling the cooling system, use the proper mix of DEX-COOL® and water. Check for leaks.
  12.  

5.7L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator fan assembly
     
    Accessory drive belt
     
    Water pump hoses
     
    Water pump mounting bolts
     
    Water pump and gaskets
     

  6.  

To install:

  1. Install the water pump and gaskets. Tighten the bolts as follows:
    1. Step 1: All bolts to 11 ft. lbs. (15 Nm).
    2.  
    3. Step 2: All bolts to 22 ft. lbs. (30 Nm).
    4.  

  2.  
  3. Install or connect the following:

    Water pump hoses
     
    Accessory drive belt
     
    Radiator fan assembly
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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