Chevrolet Chevette/1000 1976-1988 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



Gasoline Engine


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Fig. Fig. 1The timing belt front cover must be removed for access to the water pump



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Fig. Fig. 2Checking the timing belt tension



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Fig. Fig. 3It's necessary to remove the idler pulley before removing the water pump



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Fig. Fig. 4Water pump mounting and location on gasoline engines

  1. Disconnect the negative battery cable and remove engine drive belt(s).
  2.  
  3. Remove the engine fan, spacer (air conditioned models) and the pulley.
  4.  


WARNING
A bent or damaged fan assembly should always be replaced. Do not attempt repairs as fan balance is critical. If unbalanced, the fan could fail and break apart while in use.

  1. Remove the timing belt front cover by removing the two upper bolts, center bolt and two lower nuts.
  2.  
  3. Drain the coolant from the engine.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the lower radiator hose and the heater hose at the water pump.
  2.  
  3. Turn the crankshaft pulley so that the mark on the pulley is aligned with the 0 mark on the timing scale and that a 1 / 8 " drill bit can be inserted through the timing belt upper cover and cam gear.
  4.  
  5. Remove the idler pulley and pull the timing belt off the gear. Don't disturb crankshaft position.
  6.  
  7. Remove the water pump retaining bolts and remove the pump and gasket from the engine.
  8.  
  9. Clean all the old gasket material from the cylinder case.
  10.  

To install:

  1. With a new gasket in place on the water pump, position the water pump in place on the cylinder case and install the water pump retaining bolts.
  2.  
  3. Install the timing belt onto the cam gear.
  4.  
  5. Apply sealer to the idler pulley attaching bolt and install the bolt and the idler pulley. Turn the idler pulley counterclockwise on its mounting bolt to remove the slack in the timing belt.
  6.  
  7. Use a tension gauge to adjust timing belt tension. Check belt tension midway between the tensioner and the cam sprocket on the idler pulley side. Correct belt tension is 55 lbs. for 1976, 70 lbs. for 1977 and later. Torque the idler pulley mounting bolt to 13-18 ft. lbs.
  8.  
  9. Remove the 1 / 8 " drill bit from the upper timing belt cover and cam gear.
  10.  
  11. Install the lower radiator hose and the heater hose to the water pump.
  12.  
  13. Install the timing belt front cover.
  14.  
  15. Install the water pump pulley, spacer (if equipped) and engine fan.
  16.  
  17. Install the engine drive belt(s).
  18.  
  19. Refill the cooling system.
  20.  
  21. Connect the battery negative cable.
  22.  
  23. Start the engine and check for leaks.
  24.  

Diesel Engine


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Fig. Fig. 5Unfasten the retaining bolts, then ...



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Fig. Fig. 6... remove the radiator fan



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Fig. Fig. 7If equipped with A/C, remove the spacer ...



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Fig. Fig. 8... then remove the pulley



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Fig. Fig. 9Turn the crankshaft to align the mark on the pulley with the 0 mark on the timing scale ...



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Fig. Fig. 10... and a 1 / 8 in. drill bit can be inserted through the timing belt upper cover and camshaft gear



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Fig. Fig. 11Unfasten the water pump retaining bolts, then ...



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Fig. Fig. 12... remove the water pump and gasket from the engine



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Fig. Fig. 13Location of the water pump retaining bolts for diesel engines

  1. Disconnect the negative battery cable and drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the fan shroud, fan assembly and the accessory drive belts.
  2.  
  3. Unscrew the retaining bolts and remove the damper pulley.
  4.  
  5. Remove the upper and lower halves of the front cover and then remove the bypass hose at the pump.
  6.  
  7. Unscrew the pump retaining bolts and remove the pump assembly.
  8.  
  9. Installation is the reverse of the removal procedure.
  10.  

 
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