Cavalier, Sunfire 2001-2005

Removal & Installation

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2.2L (VIN 4) Engine



  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
     
    Water pump pulley bolts, loosen
     
    Accessory drive belt
     
    Water pump pulley
     
    Surge tank hose
     
    Water pump bolts, pump and gasket

    Click image to see an enlarged view

    Fig. Exploded view of the water pump mounting-2.2L (VIN 4) engine

     

  6.  

To install:

  1. Apply a thin bead of sealer around the outer edge of the water pump gasket seating area and place the gasket on the pump.
  2.  
  3. Install or connect the following:

    Water pump. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Water pump pulley and hand-tighten the bolts
     
    Surge tank hose
     
    Accessory drive belt
     
    Water pump pulley bolts. Torque the bolts to 22 ft. lbs. (30 Nm).
     

  4.  
  5. Connect the negative battery cable.
  6.  
  7. Refill and bleed the cooling system.
  8.  

2.2L (VIN F) Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. If equipped with an automatic transmission, remove the exhaust manifold.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the right front tire.
  8.  
  9. Remove the front fender liner.
  10.  
  11. Remove the access plate on the water pump sprocket from the timing cover.
  12.  
  13. Install water pump holding tool J 43651 to the water pump sprocket.

    Click image to see an enlarged view

    Fig. Install water pump holding tool J 43651 to the water pump sprocket-2.2L (VIN F) engine

  14.  
  15. Use the access plate bolts to secure the pump holding tool to the engine front cover.
  16.  
  17. Remove the bolts that secure the sprocket to the water pump.
  18.  
  19. Remove the bolt attaching the engine block to the water pump.
  20.  
  21. Remove the bolt attaching the engine front cover to the water pump.
  22.  
  23. Remove the feed pipe that joins the thermostat housing to the water pump.
  24.  
  25. Remove the 2 bolts that secure the water pump to the engine block.
  26.  
  27. Remove the water pump.
  28.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the water pump-2.2L (VIN F) engine

  1. Use a threaded stud in the hub to align the hub to the water pump sprocket.
  2.  
  3. Install the water pump.
    NOTE
    Make sure to use the correct fastener in the correct location. Replacement fasteners must be the correct part number.

  4.  
  5. Install the 2 bolts that secure the water pump to the engine block and tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the feed pipe that joins the thermostat housing to the water pump.
  8.  
  9. Install the engine front cover bolt and the bolt that attaches the engine block to the water pump. Torque the bolts to 15 ft. lbs. (20 Nm)
  10.  
  11. Install 2 of the bolts that secure the water pump sprocket to the water pump.
  12.  
  13. Remove the threaded stud.
  14.  
  15. Install the last bolt and tighten to 89 inch lbs. (10 Nm).
  16.  
  17. Remove the holding tool.
  18.  
  19. Install the access plate on the water pump sprocket to the timing cover.
  20.  
  21. Install the bolts that secure the access plate to the timing cover. Torque the bolts to 89 inch lbs. (10 Nm) on 2002-04 models or 62 inch lbs. (7 Nm) on 2005 models.
  22.  
  23. Install the front fender liner and wheel.
  24.  
  25. If equipped with an automatic transmission, install the exhaust manifold.
  26.  
  27. Fill the cooling system.
  28.  

2.4L Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    WARNING
    DO NOT rotate the flex coupling more than 4 degrees or damage may occur.



    Negative battery cable
     
    Oxygen (O 2 S) sensor electrical connector
     
    Upper exhaust manifold heat shield
     
    Exhaust manifold brace-to-manifold bolt
     
    Manifold-to-exhaust pipe spring loaded bolts
     
    Both radiator outlet pipe-to-water pump cover bolts
     
    Exhaust manifold pipe
     



    Radiator outlet pipe from the oil pan
     
    Brake vacuum pipe from the camshaft housing
     
    Exhaust manifold from the cylinder head
     
    Front cover
     
    Timing chain tensioner
     
    Water pump cover and water pump as an assembly
     

  6.  
  7. Separate the water pump from the water pump cover.

    Click image to see an enlarged view

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

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Lubricate the splines with clean grease



    Water pump with a new gasket to the cover and tighten the bolts finger-tight
     



    Water pump and cover assembly using new gaskets and tighten the fasteners finger-tight
     

  2.  
  3. Torque the bolts in the following sequence;
    1. Pump assembly-to-chain housing nuts: 19 ft. lbs. (26 Nm).
    2.  
    3. Pump cover-to-pump assembly: 124 inch lbs. (14 Nm).
    4.  
    5. Cover-to-block, bottom bolt first: 19 ft. lbs. (26 Nm).
    6.  

  4.  
  5. Install or connect the following:

    Timing chain tensioner
     
    Front cover. Torque the bolts to 97 inch lbs. (11 Nm).
     
    Exhaust manifold with a new gasket. Torque the bolts to 31 ft. lbs. (42 Nm).
     
    Brake vacuum pipe to the camshaft housing
     
    Radiator outlet pipe to the water pump cover. Torque the bolts to 125 inch lbs. (14 Nm).
     
    Radiator outlet pipe to the oil pan. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust pipe to the manifold. Tighten the exhaust pipe flange bolts evenly and gradually to avoid binding, until fully seated. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Exhaust manifold brace to the manifold. Torque the bolts to 41 ft. lbs. (56 Nm).
     
    Upper heat shield. Torque the bolts to 125 inch lbs. (14 Nm).
     
    O 2 S electrical connector
     
    Negative battery cable
     

  6.  
  7. Refill the cooling system until it comes out of the heater hose outlet; then connect the heater hose.
  8.  
  9. Start the engine. Run the vehicle until the thermostat opens, refill the radiator and recovery tank, then turn the engine OFF .
  10.  
  11. Once the vehicle has cooled, recheck the coolant level.
  12.  

 
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