GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Water Pump

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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.

1.8L, 2.0L and 2.2L OHV Engines

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly drain the cooling system into an approved container.
  4.  
  5. Remove all accessory drive belts or the serpentine belt.
  6.  
  7. Remove the alternator and bracket. For details, please refer to Engine Electrical of this repair guide.
  8.  
  9. Unscrew the water pump pulley mounting bolts and then pull off the pulley.
  10.  
  11. Unfasten the mounting bolts, then remove the water pump.
  12.  
  13. Using a putty knife, clean the gasket mounting surfaces.
  14.  



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Fig. Fig. 1: Water pump mounting - 1982 1.8L OHV engine shown



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Fig. Fig. 2: Location and mounting of the water pump on the 2.0L and 2.2L OHV engines

To install:
  1. Place a 1 / 8 in. (3mm) wide bead of RTV sealant on the water pump sealing surface or install a new gasket, on models so equipped. Install the pump and tighten the retaining bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the water pump pulley, then tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  4.  
  5. As outlined in Engine Electrical , install the alternator and bracket.
  6.  
  7. Install the drive belts or serpentine belt, as applicable.
  8.  
  9. Fill the cooling system to the proper level.
  10.  
  11. Connect the negative battery cable, then start the engine and check for leaks.
  12.  

1.8L and 2.0L OHC Engines

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Properly drain the engine cooling system into an approved container.
  4.  
  5. Remove the timing belt as described later in this section.
  6.  
  7. Remove the timing belt rear protective covers.
  8.  
  9. Disconnect the hose from the water pump.
  10.  
  11. Unfasten the retaining bolt(s), then remove the water pump and seal ring. Inspect the ring for damage and replace if necessary. Clean the pump mating surfaces.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Water pump location on the 1.8L and 2.0L OHC engines

To install:
  1. Install the seal ring and water pump. Do not fully tighten the retaining bolts. They will be tightened to specification during installation of the timing belt.
  2.  
  3. Connect the hose to the water pump.
  4.  
  5. Install the timing belt rear protective covers.
  6.  
  7. Install the timing belt and adjust it to specifications, as outlined later in this section. Tighten the water pump mounting bolts to 18-21 ft. lbs. (21-25 Nm).
  8.  
  9. Fill the engine cooling system to the proper level.
  10.  
  11. Connect the negative battery cable, then start the engine and check for leaks and make sure the coolant level is correct.
  12.  

2.8L and 3.1L Engines

See Figure 4

  1. Disconnect battery negative cable.
  2.  
  3. Properly drain and recover the cooling system into an approved container.
  4.  
  5. Disconnect the serpentine belt at the water pump pulley.
  6.  
  7. On 1985-86 models, if equipped with A/C, disconnect the wires at the air conditioning pressure cycling switch and remove the cycling switch.
  8.  
  9. Unfasten the water pump pulley retaining bolts, then remove the pulley.
  10.  
  11. Unfasten the pump attaching bolts, then remove the water pump.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: Water (coolant) pump mounting - 2.8L and 3.1L engines

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Using a new gasket, install the water pump, then tighten the pump to block bolts to 18 ft. lbs. (24 Nm) for 2.8L engines and to 89 inch lbs. (10 Nm) for 3.1L engines.
  4.  
  5. Install the water pump pulley. Tighten the mounting bolt to 15 ft. lbs. (20 Nm).
  6.  
  7. On 1985-86 models, if equipped, install the air conditioning pressure cycling switch and connect the wires.
  8.  
  9. Install the serpentine belt.
  10.  
  11. Fill the cooling system to the proper level.
  12.  
  13. Connect the negative battery cable, then start the engine and check for leaks.
  14.  

 
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