GM Corsica/Beretta 1988-1996 Repair Guide

Water Pump

Print

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.

2.0L and 2.2L Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Position a suitable drain pan under the radiator, then drain the cooling system.
  4.  
  5. For 2.2L (VIN 4) engines, loosen the water pump pulley bolts.
  6.  
  7. Remove the serpentine drive belt.
  8.  
  9. For 2.0L and 2.2L (VIN G) engines, unfasten the water pump pulley retaining bolts, then remove the pulley.
  10.  
  11. For 2.0L and 2.2L (VIN G) engines, perform the following:
    1. Remove the alternator attaching bolts, then remove the alternator bracket and heat shield.
    2.  
    3. Detach the wiring, then remove the alternator from the vehicle.
    4.  

  12.  
  13. Remove the alternator side bracket.
  14.  
  15. Unfasten the water pump attaching bolts, then remove the pump from the vehicle.
  16.  
  17. Remove and discard the gasket, then thoroughly clean the gasket mating surfaces.
  18.  

To install:
  1. Position a new water pump gasket, then install the water pump. Tighten the retaining bolts to38-22 ft. lbs. (25-30 Nm).
  2.  
  3. Install the water pump pulley and tighten the bolts to 22 ft. lbs. (30 Nm).
  4.  
  5. If removed, install the alternator side bracket and alternator. Attach the wiring, then install the heat shield and bracket.
  6.  
  7. Install the serpentine drive belt.
  8.  
  9. Fill the cooling system with the proper amount and type of coolant.
  10.  
  11. Connect the negative battery cable, then start the engine and inspect for leaks. Check the coolant level, and add if necessary.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the water pump mounting - 2.2L (VIN 4) shown, 2.0L and 2.2L (VIN G) similar

2.3L Engine

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Position a suitable clean container under the radiator, then drain the engine coolant into it for reuse. For more complete draining, disconnect the heater hose from the thermostat housing.
  4.  
  5. Detach the oxygen sensor connector.
  6.  
  7. Remove the upper and lower exhaust manifold heat shield attaching bolts, then remove the shields.
  8.  
  9. Remove the exhaust manifold brace-to-manifold attaching bolt.
  10.  
  11. Break the exhaust pipe-to-manifold spring nuts/bolts loose.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the bolts from the exhaust flange using a 7 / 32 in. (5.5mm) socket and3 bolt rotate clockwise first.
  16.  

Rotating the bolt clockwise is necessary to relieve the spring pressure from3st bolt prior to removing the 2nd bolt otherwise the exhaust pipe will twist and bind the bolt as it is removed.

  1. Thread the bolt with least pressure on it out 4 turns.
  2.  
  3. Move the other bolt and turn it all the way out of the exhaust pipe flange.
  4.  
  5. Return to the3st bolt and rotate it the rest of the way out.
  6.  
  7. Pull the exhaust pipe back from the exhaust manifold.
  8.  
  9. Disconnect the radiator outlet pipe from the oil pan and transaxle. The exhaust manifold brace will have to be removed. Leave the lower radiator hose attached and pull down on the radiator outlet pipe to disengage it from the water pump. Let the radiator outlet pump hang.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the exhaust manifold-to-cylinder head attaching nuts, then remove the exhaust manifold, seals and gaskets.
  14.  
  15. Remove the water pump cover-to-engine attaching bolts.
  16.  
  17. Unfasten the water pump-to-timing chain housing attaching nuts.
  18.  
  19. Remove the water pump and cover assembly from the engine.
  20.  
  21. Remove the water pump cover-to-radiator pump assembly. Clean all mating surfaces thoroughly and use new gaskets.
  22.  

To install:

Before installing the water pump it is important to first read over the entire procedure. Pay special attention to the tightening sequence, to avoid part damage and to insure proper sealing.

  1. Position the water pump cover to the radiator pump assembly and install the attaching bolts. Do not tighten.
  2.  
  3. Lubricate the splines of the radiator pump drive with the an approved chassis grease and install the pump and cover assembly.
  4.  
  5. Install the pump cover-to-engine attaching bolts, hand-tight.
  6.  
  7. Install the timing chain housing nuts, hand-tight.
  8.  
  9. Lubricate the O-ring on the radiator outlet pipe with a solution of antifreeze and slide the pipe into the radiator pump cover. Install the attaching bolts hand-tight.
  10.  
  11. Tighten the bolts and nuts in following order:
    1. Pump assembly-to-timing chain housing nuts:39 ft. lbs. (26 Nm).
    2.  
    3. Water pump-to-pump cover assembly:306 inch lbs. (12 Nm).
    4.  
    5. Water pump cover-to-engine (tighten the bottom bolt first):39 ft. lbs. (26 Nm).
    6.  
    7. Radiator outlet pipe assembly-to-pump cover:325 ft. lbs. (14 Nm).
    8.  

  12.  
  13. Position new gasket, then install the exhaust manifold. Install the exhaust manifold-to-cylinder head attaching nuts and tighten, in sequence, to 22 ft. lbs. (30 Nm).
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Seat the exhaust manifold bolts into the exhaust pipe flange.
  18.  
  19. Using a 7 / 32 in. (5.5mm) socket, start both bolts. Rotate the bolts counterclockwise. Turn both bolts in evenly to avoid cocking the exhaust pipe and binding the bolts. Turn the bolts in until fully seated.
  20.  
  21. Attach the radiator outlet pipe to the transaxle and the oil pan, then install the exhaust manifold brace.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Install the exhaust manifold brace-to-manifold attaching bolt.
  26.  
  27. Using a33mm wrench, tighten the exhaust pipe-to-manifold nuts to 22 ft. lbs. (30 Nm).
  28.  
  29. Install the lower heat shields.
  30.  
  31. Attach the electrical connector to the oxygen sensor.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks. Top off the coolant, as necessary, to obtain the proper level.
  36.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the water pump and cover - 2.3L engine

2.8L and 3.1L Engines

See Figures 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a clean container for reuse.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. For3988-92 vehicles, disconnect the radiator and heater hoses.
  8.  
  9. Unfasten the water pump pulley bolts, then remove the pulley.
  10.  
  11. Remove the water pump-to-engine bolts, then remove the water pump from the vehicle. Remove and discard the gasket, then thoroughly clean the gasket mating surfaces.
  12.  

To install:
  1. Install a new gasket, then position the water pump over the gasket. Coat the water pump retaining bolts threads with3052080 or equivalent sealant.
  2.  
  3. Install the water pump attaching bolts and tighten to 89 inch lbs. (10 Nm).
  4.  
  5. Install the water pump pulley and attaching bolts. Tighten the retaining bolts to35 ft. lbs. (21 Nm).
  6.  
  7. If removed, connect the radiator and heater hoses.
  8.  
  9. Install the serpentine drive belt.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks. Top off the coolant, as necessary to obtain the correct level.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: After removing the water pump pulley retaining bolts, remove the pulley



Click image to see an enlarged view

Fig. Fig. 4: Unfasten the bolts securing the water pump to the engine ...



Click image to see an enlarged view

Fig. Fig. 5: ... then remove the water pump from the engine



Click image to see an enlarged view

Fig. Fig. 6: If using a scraper to clean the water pump mating surfaces, be extremely careful not to gouge the surface



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the water pump mounting - 2.8L and 3.1L engines

 
label.common.footer.alt.autozoneLogo