GM Corvette 1984-1996 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



5.7L (VIN 8) Engine
1984-88 vehicles
  1. Take your vehicle to a reputable repair shop to have the A/C system discharged.
  2.  
  3. Disconnect the negative battery cable. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine cooling system into a suitable container.
  6.  
  7. Remove the serpentine drive belt, as outlined in General Information & Maintenance of this repair guide.
  8.  
  9. Remove the water pump pulley and the AIR pump pulley.
  10.  
  11. Remove the air management valve adapter.
  12.  
  13. Remove the AIR pump.
  14.  
  15. Disconnect the fuel inlet and return lines.
  16.  
  17. Remove the rear A/C compressor braces. Remove the lower A/C compressor mounting bolt. Remove the A/C compressor and idler pulley bracket nuts.
  18.  
  19. Detach the A/C compressor wiring.
  20.  
  21. Slide the mounting bracket forward and remove the rear A/C compressor bolt.
  22.  
  23. Remove the A/C compressor from the vehicle.
  24.  
  25. Remove the right and left AIR hoses at the check valve.
  26.  
  27. Remove the AIR pipe from the intake and power steering reservoir bracket.
  28.  
  29. Remove the power steering reservoir bracket, including the top alternator bolt.
  30.  
  31. Remove the lower AIR bracket from the water pump.
  32.  
  33. Disconnect the lower radiator and heater hoses from the water.
  34.  
  35. Unfasten the retainers, then remove the water pump. Remove and discard the gasket and thoroughly clean the gasket mating surfaces.
  36.  

To install:
  1. If installing a new water pump, transfer the heater hose fitting to the new pump.
  2.  
  3. Install the water pump to the block, with new gaskets, and secure with the attaching bolts. Tighten the bolts to 25-35 ft. lbs. (33-47 Nm).
  4.  
  5. The remainder of installation is the reverse of the removal procedure.
  6.  
  7. Fill the radiator with the proper type and amount of coolant.
  8.  
  9. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  10.  
  11. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  12.  

1989-91 vehicles
  1. Disconnect the negative battery cable. Properly relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner and air intake duct assembly.
  4.  
  5. Detach the MAF sensor electrical connector.
  6.  
  7. Remove the surge tank pressure cap, then drain the engine cooling system into a suitable container.
  8.  
  9. Relieve the serpentine belt tension with a 1 / 2 in. breaker bar, then remove the belt.
  10.  
  11. Remove the water pump damper and pulley.
  12.  
  13. Unfasten the A/C compressor mounting bolts.
  14.  
  15. Remove the AIR pump mounting bolts.
  16.  
  17. Remove the cover from the AIR control valve.
  18.  
  19. Disconnect the upper hose from the AIR control valve, then detach the electrical connector from the valve.
  20.  
  21. Unfasten the nut retaining the AIR pipe and control valve, then reposition the assembly.
  22.  
  23. Disconnect the heater hose from the pump.
  24.  
  25. Unfasten the belt tensioner bolt.
  26.  
  27. Disconnect the fuel lines.
  28.  
  29. Remove the AIR pump bracket bolts. Unfasten the nut retaining the AIR pump brace.
  30.  
  31. Unfasten the lower radiator hose clamp, then disconnect the hose.
  32.  
  33. Remove the A/C compressor bracket mounting bolts.
  34.  
  35. Remvoe the bolts and stud nuts holding the water pump to the engine block.
  36.  
  37. Unfasten the retainers, then remove the water pump. Remove and discard the gasket and thoroughly clean the gasket mating surfaces.
  38.  

To install:
  1. If installing a new water pump, transfer the heater hose fitting to the new pump and tighten the fitting to 27 ft. lbs. (37 Nm).
  2.  
  3. Install the water pump to the block, with new gaskets, and secure with the attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install the AIR pipe retaining bracket bolt and the A/C compressor bracket mounting bolts.
  6.  
  7. Connect the lower radiator hose and secure with the hose clamp.
  8.  
  9. Install the AIR pump bracket retaining bolts.
  10.  
  11. Connect the fuel lines.
  12.  
  13. Install the belt tensioner bolt.
  14.  
  15. Attach the heater hose to the pump and secure with the hose clamp.
  16.  
  17. Attach the control valve electrical connector. Attach the upper hose onto the AIR control valve. Install the AIR control valve cover.
  18.  
  19. Install the AIR pump bolts and the nut retaining the pump brace. Tighten the nut to 25 ft. lbs. (33 Nm).
  20.  
  21. Install the A/C compressor mounting bolts.
  22.  
  23. Install the water pump damper and pulley.
  24.  
  25. Install the serpentine drive belt.
  26.  
  27. Attach the MAF sensor electrical connector.
  28.  
  29. Fill the radiator with the proper type and amount of coolant. Connect the negative battery cable.
  30.  
  31. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  32.  
  33. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  34.  

5.7L (VIN J) Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a suitable container.
  4.  
  5. Remove the air cleaner and air intake duct assembly.
  6.  
  7. Unfasten the screws retaining the throttle body extension to the throttle body, then remove the extension and gasket.
  8.  
  9. Loosen the clamps, then disconnect the hoses from the coolant outlets, radiator inlet and inlet pipe.
  10.  
  11. Remove the hose and inlet pipe assembly from the vehicle.
  12.  
  13. Remove the serpentine drive belt.
  14.  
  15. Unfasten the bolt retaining the belt tensioner to the pump, then remove the tensioner from the vehicle.
  16.  
  17. Loosen the engine hose clamp, then remove the hose from the pump.
  18.  
  19. Unfasten the bolts securing the alternator lower mounting bracket, then remove the bracket from the vehicle.
  20.  

The water pump is secured with 4 different types and sizes of bolts. Make sure to note the installed positions of the bolts before removing them.

  1. Remove the water pump-to-front cover mounting bolts.
  2.  
  3. Unfasten the bolt securing the A/C compressor to the water pump, then remove the water pump from the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: The water pumps on these vehicles are mounted with 4 different sizes of bolts

  1. If you are installing a new water pump, transfer the water pump pulley to the new pump. Tighten the pulley mounting bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Remove and discard the gasket, then thoroughly clean the mating surfaces.
  4.  

To install:
  1. Position a new gasket, then install the water pump and retaining bolts. Make sure the bolts are in the same position as they were removed. Finger-tighten the mounting bolts.
  2.  
  3. Install the bolt securing the A/C compressor to the water pump and finger-tighten the bolts.
  4.  
  5. Tighten the water pump and A/C compressor bolts to 20 ft. lbs. (27 Nm).
  6.  
  7. Connect the engine hose and secure with the hose clamp.
  8.  
  9. Install the alternator mounting bolt and bracket bolts. Tighten the mounting bolts to 39 ft. lbs. (52 Nm) and the bracket bolts to 20 ft. lbs. (26 Nm).
  10.  
  11. Install the belt tensioner and secure with the mounting bolt. Tighten the tensioner-to-cylinder case bolt to 45 ft. lbs. (60 Nm).
  12.  
  13. Install the serpentine drive belt.
  14.  
  15. Install the hose and inlet pipe assembly and secure with the retaining clamps.
  16.  
  17. Install the throttle body extension gasket, extension and retaining screws. Tighten the screws to 53 inch lbs. (6 Nm).
  18.  
  19. Install the air cleaner and air intake duct assembly.
  20.  
  21. Fill the radiator with the proper type and amount of coolant. Connect the negative battery cable.
  22.  
  23. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  24.  
  25. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  26.  

5.7L (VIN P and 5) Engines

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the Intake Air Temperature (IAT) sensor electrical connector.
  4.  
  5. Remove the air cleaner assembly and air intake duct.
  6.  
  7. Drain the cooling system into a suitable container. If necessary, remove the knock sensors for complete draining.
  8.  
  9. Unfasten the clamps, then disconnect the inlet and outlet radiator hoses from the water pump.
  10.  
  11. Remove the throttle body hose from the T-fitting.
  12.  
  13. Disconnect the heater hose from the water pump.
  14.  
  15. Detach the Engine Coolant Temperature (ECT) sensor electrical connector. Remove the ECT sensor wiring harness retainer from the front of the water pump.
  16.  
  17. Remove the serpentine drive belt.
  18.  
  19. Unfasten the bolts holding the water pump to the engine block, then remove the water pump from the vehicle.
  20.  
  21. Remove and discard the gasket, then thoroughly clean the mating surfaces.
  22.  
  23. Inspect the O-ring seals on the water pump driveshaft and front cover for cracks and dryness. If any of the O-rings are damaged, they must be replaced.
  24.  
  25. If replacing the water pump, transfer the ECT sensor to the new pump. Tighten the sensor to 17 ft. lbs. (23 Nm).
  26.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the water pump and related components-5.7L (VIN P and 5) engines

To install:

Before you assemble the coupling to the water pump, apply a light coat of grease to the seals and splines.

  1. Install the coupling with the groove toward the engine.
  2.  
  3. Install new gaskets with the tabs up, the water pump with the drive coupling and the mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Install the serpentine drive belt.
  6.  
  7. Instlal the ECT sensor wire harness retainer on the front of the water pump, then attach the electrical connector.
  8.  
  9. Connect the heater hose to the water pump.
  10.  
  11. Attach the inlet and outlet radiator hoses and clamps to the water pump.
  12.  
  13. Install the throttle body hose at the T-fitting.
  14.  
  15. Install the air cleaner and intake duct.
  16.  
  17. Fill the radiator with the proper type and amount of coolant. Connect the negative battery cable.
  18.  
  19. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  20.  
  21. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  22.  

 
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