CTS 2006-2007, CTS-V 2005-2007, DTS 2006-2007

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.  

4.6L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the fuel injector sight shield.
  8.  
  9. Remove the water pump drive belt.
  10.  
  11. Reposition the brake booster vacuum hose clamp at the water pump housing.
  12.  
  13. Remove the brake booster vacuum hose from the water pump housing.
  14.  
  15. Remove the oil level indicator tube nut.
  16.  
  17. Reposition the oil level indicator tube.
  18.  
  19. Remove the transaxle vent hose clip from the bracket.
  20.  
  21. Remove the throttle body bolts.
  22.  
  23. Remove the bracket.
  24.  
  25. Remove the throttle body.
  26.  
  27. Remove and discard the throttle body seal.
  28.  
  29. Loosen the throttle body plenum duct clamp.
  30.  
  31. Remove and discard the throttle body plenum duct.
  32.  
  33. Remove the fuel rail bracket nut at the rear left lift bracket.
  34.  
  35. Reposition the surge tank inlet hose clamp at the fitting.
  36.  
  37. Remove the surge tank inlet hose from the fitting.
  38.  
  39. Remove the engine coolant outlet fitting.
  40.  
  41. Remove the rear left lift bracket bolt.
  42.  
  43. Remove the rear left lift bracket.
  44.  
  45. Remove the exhaust gas recirculation (EGR) valve shield nuts.
  46.  
  47. Remove the EGR valve shield.
  48.  
  49. Remove the EGR valve bolts.
  50.  
  51. Remove the EGR valve.
  52.  
  53. Remove and discard the EGR valve gasket.
  54.  
  55. Disconnect the engine harness electrical connector from the engine valley electrical connector.
  56.  
  57. Raise and support the vehicle.
  58.  
  59. Disconnect the EGR inlet pipe nut from the exhaust manifold front pipe.
  60.  
  61. Lower the vehicle.
  62.  
  63. Remove the EGR inlet pipe bolt from the water pump housing.
  64.  
  65. Remove and discard the EGR inlet pipe.
  66.  
  67. Remove the Evaporative Emission (EVAP) canister purge solenoid valve bolt.
  68.  
  69. Remove the EVAP canister purge solenoid valve.
  70.  
  71. Remove the MAP sensor bracket.
  72.  
  73. Remove the MAP sensor.
  74.  
  75. Reposition the radiator inlet hose clamp at the water pump housing.
  76.  
  77. Remove the radiator inlet hose from the water pump housing.
  78.  
  79. Reposition the radiator outlet hose clamp at the thermostat housing.
  80.  
  81. Remove the radiator outlet hose from the thermostat housing.
  82.  
  83. Remove the water pump belt tensioner studs.
  84.  
  85. Remove the water pump belt tensioner.
  86.  
  87. Reposition the heater outlet hose clamp at the heater pipe.
  88.  
  89. Remove the heater outlet hose from the heater pipe.
  90.  
  91. Remove the water pump cover bolt and studs.
  92.  
  93. Remove the water pump cover.
  94.  
  95. Loosen the water pump housing bolts.
  96.  
  97. Remove the water pump housing.

    Click image to see an enlarged view

    Fig. Water pump housing removal 4.6L engine

  98.  
  99. Remove the water pump housing gaskets and bolts.
  100.  
  101. With the water pump housing on the bench, remove the water pump bolts.
  102.  
  103. Remove the water pump from the water pump housing.

    Click image to see an enlarged view

    Fig. Water pump removal from housing assembly 4.6L engine

  104.  
  105. Remove and discard the water pump O-ring.
  106.  

To install:

  1. Install a NEW water pump O-ring to the water pump.
  2.  
  3. Install the water pump and tighten mounting bolts to 89 inch lbs. (10 Nm).
  4.  
  5. With the water pump housing on the bench, install the bolts in the locations shown:

    Bolt  (1) length 1.6024 inch  (40.7 mm).
     
    Bolts (2) length 3.6220 inch (92.0 mm).
     
    Bolts (3) length 4.2913 inch (109.0 mm).
     
    Bolts (4) length 4.5276 inch (115.0 mm).

    Click image to see an enlarged view

    Fig. Water pump bolts locations shown

     

  6.  
  7. With the housing still on the bench, install the NEW water pump housing gasket onto the bolts.
  8.  
  9. Position the water pump housing to the engine and hand start the bolts.
  10.  
  11. Tighten the water pump housing bolts.
  12.  
  13. Tighten the bolts in the sequence shown to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Water pump housing bolt tightening sequence

  14.  
  15. Install the water pump cover.
  16.  
  17. Install the water pump cover bolt and studs.
  18.  
  19. Tighten the bolt/studs to 89 inch lbs. (10 Nm).
  20.  
  21. Install the heater outlet hose to the heater pipe.
  22.  
  23. Position the heater outlet hose clamp at the heater pipe.
  24.  
  25. Position the water pump belt tensioner.
  26.  
  27. Install the water pump belt tensioner studs and tighten to 89 inch lbs. (10 Nm).
  28.  
  29. Install the radiator outlet hose to the thermostat housing.
  30.  
  31. Position the radiator outlet hose clamp at the thermostat housing.
  32.  
  33. Install the radiator inlet hose to the water pump housing.
  34.  
  35. Position the radiator inlet hose clamp at the water pump housing.
  36.  
  37. Install the MAP sensor.
  38.  
  39. Install the MAP sensor bracket.
  40.  
  41. Install the MAP sensor bracket bolt and tighten to 89 inch lbs. (10 Nm).
  42.  
  43. Install the EVAP canister purge solenoid valve.
  44.  
  45. Install the EVAP canister purge solenoid valve bolt and tighten to 89 inch lbs. (10 Nm).
    WARNING
    The EGR valve inlet pipe incorporates a crush seal connection at the water pump housing. The EGR valve inlet pipe must be replaced if disconnected from the water pump housing.

  46.  
  47. Hand start the NEW EGR inlet pipe nut at the exhaust manifold front pipe.
  48.  
  49. Install the EGR inlet pipe and bolt to the water pump housing. Tighten the nut to 44 ft. lbs. (60 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
  50.  
  51. Raise and support the vehicle.
  52.  
  53. Tighten the EGR inlet pipe nut.
  54.  
  55. Tighten the nut to 44 ft. lbs. (60 Nm) .
  56.  
  57. Lower the vehicle.
  58.  
  59. Connect the engine harness electrical connector (1) to the engine valley electrical connector.
  60.  
  61. Install the NEW EGR valve gasket.
  62.  
  63. Install the EGR valve.
  64.  
  65. Install the EGR valve bolts and tighten to 18 ft. lbs. (25 Nm).
  66.  
  67. Install the EGR valve shield.
  68.  
  69. Install the EGR valve shield nuts and tighten to 89 inch lbs. (10 Nm).
  70.  
  71. Position the rear left lift bracket to the water pump housing.
  72.  
  73. Install the rear left lift bracket bolt and tighten to 18 ft. lbs. (25 Nm).
  74.  
  75. Install the engine coolant outlet fitting, tighten the fitting to 35 ft. lbs. (47 Nm).
  76.  
  77. Install the surge tank inlet hose to the fitting.
  78.  
  79. Position the surge tank inlet hose clamp at the fitting.
  80.  
  81. Install the fuel rail bracket nut at the rear left lift bracket. Tighten the nut to 89 inch lbs. (10 Nm).
    WARNING
    DO NOT use any type of sealant between the plenum and the water pump housing.

  82.  
  83. Install a NEW throttle body plenum duct.
  84.  
  85. Tighten the throttle body plenum duct clamp to 20 inch lbs. (2.25 Nm).
  86.  
  87. Install a NEW throttle body seal.
  88.  
  89. Install the throttle body.
  90.  
  91. Install the throttle body bracket.
  92.  
  93. Install the throttle body bolts and tighten to 89 inch lbs. (10 Nm).
  94.  
  95. Install the transaxle vent hose clip to the bracket.
  96.  
  97. Position the oil level indicator tube.
  98.  
  99. Install the oil level indicator tube nut and tighten to 89 inch lbs. (10 Nm).
  100.  
  101. Install the brake booster vacuum hose to the water pump housing.
  102.  
  103. Position the brake booster vacuum hose clamp at the water pump housing.
  104.  
  105. Install the water pump drive belt.
  106.  
  107. Install the air cleaner.
  108.  
  109. Fill the cooling system.
  110.  
  111. Install the fuel injector sight shield.
  112.  

5.7L & 6.0L 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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