GM Prizm/Nova 1985-1993 Repair Guide

Water Pump

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REMOVAL & INSTALLATION



1985-88 All Engines

See Figures 1 and 2

  1. Drain the engine coolant by opening the radiator and engine block draincocks. Collect the coolant in clean containers and save for reuse.
  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. On the 1988 VIN Code 5 engine, remove the power steering drive belt.
  2.  
  3. Loosen the water pump pulley bolts.
  4.  
  5. Loosen the alternator locking bolt and the pivot nut.
  6.  
  7. Move the alternator to its loosest position and remove the belt.
  8.  
  9. On the 1985-88 VIN Code 4 engine, remove the power steering drive belt.
  10.  
  11. Remove the 4 bolts on the water pump pulley and remove the pulley.
  12.  
  13. Disconnect the water inlet and the water bypass hoses from the water inlet pipe.
  14.  
  15. Disconnect and remove the water inlet pipe by removing the 2 clamp bolts and the 2 nuts at the back of the pump. Remove the O-ring from the back of the pump.
  16.  
  17. Remove the mounting bolt for the dipstick tube; remove the tube and dipstick. Immediately plug the hole in block to prevent fluid from polluting the oil.
  18.  


WARNING
During the following steps, if coolant should get by the plug in the dipstick hole and run into the motor, the engine oil MUST be changed before starting the motor. Failure to do so can damage the engine bearings.

  1. On 1985-88 VIN Code 4 engine, remove the No. 1 (upper) timing belt cover. On 1988 VIN Code 5 engines, both the No. 2 (lower) and No. 3 (middle) timing belt covers must be removed.
  2.  
  3. Remove the water pump bolts and the water pump.
  4.  

To install:
  1. Place the water pump gasket (O-ring) on the block and install the pump. Tighten the mounting bolts to 11 ft. lbs.
  2.  
  3. Install the timing belt cover(s), making sure they are properly seated and not rubbing on the belt or other moving parts.
  4.  
  5. Install a new seal (O-ring) on the dipstick tube and lightly coat it with engine oil. Remove the plug and install the dipstick tube and dipstick; secure the mounting bolt.
  6.  
  7. Using a new O-ring, install the inlet pipe to the water pump.
  8.  
  9. Attach the clamps and bolts to hold the pipe in place.
  10.  
  11. Connect the water inlet and water bypass hoses to the inlet pipe.
  12.  
  13. Install the water pump pulley and tighten the 4 pulley bolts finger tight.
  14.  
  15. For 1985-88 VIN Code 4 engines, install the power steering drive belt.
  16.  
  17. Install the drive belts on all the pulleys and adjust all of them to the correct tension.
  18.  
  19. With the belts in place and adjusted, the water pump pulley will now resist turning. Tighten the pulley bolts to 16-18 ft. lbs.
  20.  
  21. For the 1988 VIN Code 5 engine, install the power steering belt and adjust to the proper tension.
  22.  
  23. Confirm that the draincocks are closed on the engine block and radiator. Refill the engine coolant.
  24.  
  25. Start the engine and check for leaks.
  26.  



Click image to see an enlarged view

Fig. Fig. 1: Water pump components - 1985-88 VIN Code 4 engine



Click image to see an enlarged view

Fig. Fig. 2: Water pump components - 1988 VIN Code 5 engine and 1989-90 VIN code 6 engine

1989-92 All Engines

See Figure 2

  1. Remove the radiator cap. Drain the engine coolant by opening the radiator and engine block draincocks. Collect the coolant in clean containers and save for reuse.
  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. Raise and safely support the vehicle on jackstands.
  2.  
  3. Remove the 2 nuts for the rear motor mount.
  4.  
  5. Lower the vehicle to the ground.
  6.  
  7. Remove the windshield washer fluid container.
  8.  
  9. If so equipped, remove the cruise control bracket with the control module.
  10.  
  11. Remove the through bolt for the right motor mount.
  12.  
  13. Place a jack under the engine. Use a piece of wood between the engine and the jack.
  14.  
  15. Raise the engine slowly and carefully. Keep a close watch on lines and cables. The engine need only be raised enough to gain access to various nuts and bolts.
  16.  
  17. Loosen the water pump pulley bolts, but leave them in place.
  18.  
  19. Loosen the alternator lock bolt and pivot nut; swing the alternator towards the engine and remove the drive belt.
  20.  
  21. Loosen the pivot bolts and the lock bolt for the power steering pump and move it towards the engine; remove the power steering belt.
  22.  
  23. With the belts removed, the water pump pulley may be removed from the pump.
  24.  
  25. Lower the jack, allowing the engine to return to place.
  26.  
  27. Remove the water inlet and water bypass hoses from the water inlet pipe.
  28.  
  29. Remove the clamp holding the water inlet pipe to the engine. Loosen and remove the 2 nuts holding the inlet pipe to the water pump. Remove the pipe and its O-ring.
  30.  
  31. Remove the mounting bolt for the dipstick tube; remove the tube and dipstick. Immediately plug the hole in block to prevent fluid from polluting the oil.
  32.  


WARNING
During the following steps, if coolant should get by the plug in the dipstick hole and run into the motor, the engine oil MUST be changed before starting the motor. Failure to do so can damage the engine bearings.

  1. Remove the upper timing belt cover.
  2.  

The timing belt is exposed with the cover(s) removed. Do not allow oil or coolant to contact the belt. This includes any fluid which may be accidentally transferred through rags, fingerprints, etc.

  1. Remove the 3 water pump bolts and remove the water pump.
  2.  

To install:
  1. Position a new O-ring on the engine and fit the water pump. Tighten the 3 bolts to 11 ft. lbs.
  2.  
  3. Install the upper timing belt cover.
  4.  
  5. Install a new O-ring on the dipstick tube.
  6.  
  7. Remove the plug in the engine and install the tube. Tighten the mounting bolt.
  8.  
  9. Using a new O-ring, install the water inlet pipe at the back of the water pump. Tighten the 2 nuts to 14. ft. lbs.
  10.  
  11. Connect the water inlet and water bypass hoses to the water inlet pipe.
  12.  
  13. Following the same jacking procedure as before, elevate the motor with the floor jack.
  14.  
  15. Install the water pump pulley and tighten the bolts finger tight. It will be easier to do the final tightening when the belts are installed.
  16.  
  17. Install the power steering belt and adjust its tension.
  18.  
  19. Install the alternator drive belt and adjust its tension.
  20.  
  21. Tighten the water pump pulley bolts to 17 ft. lbs.
  22.  
  23. Lower the jack, allowing the engine to return to its normal place.
  24.  
  25. Install the through bolt for the right motor mount. Tighten it to 64 ft. lbs.
  26.  
  27. Reinstall the cruise control module and the bracket, if so equipped.
  28.  
  29. Raise and safely support the vehicle on jackstands.
  30.  
  31. Install the 2 nuts for the rear mount and tighten them to 38 ft. lbs.
  32.  
  33. Lower the vehicle to the ground.
  34.  
  35. Replace the washer fluid container.
  36.  
  37. Confirm that the draincocks on the radiator and engine block are closed. Refill the cooling system with coolant.
  38.  
  39. Start the engine and check for leaks. Pay particular attention to any hose or fitting which was disassembled during the repair.
  40.  
  41. After the engine is shut off, double check the drive belts for proper tension and adjust as necessary.
  42.  

1993
  1. Disconnect the negative battery cable. Drain the engine coolant from the radiator.
  2.  
  3. Remove all drive belts.
  4.  
  5. Support the engine using suitable equipment. Place a wooden block between the jack and engine. Remove the right engine mount and insulator.
  6.  
  7. Remove the No. 3 (upper) and No. 2 (middle) timing belt covers.
  8.  
  9. If equipped with power steering, raise and safely support the vehicle. Remove the front transaxle mount. Lower the vehicle, remove the cooling fan assembly.
  10.  
  11. Remove the mounting bolt for the dipstick tube; remove the tube and dipstick. Immediately plug the hole in the block to prevent fluid from contaminating the oil.
  12.  
  13. Remove the electrical connector for the coolant temperature sending unit.
  14.  
  15. Remove the 2 nuts securing the engine coolant pipe to the cylinder block.
  16.  
  17. Loosen the hose clamp and remove the coolant inlet pipe from the vehicle.
  18.  
  19. Loosen the hose clamp and remove the coolant inlet hose from the water pump.
  20.  
  21. If equipped with power steering, raise the engine and remove the mounting bolts for the water pump. Remove the water pump and O-ring from the vehicle.
  22.  

To install:
  1. Install a NEW O-ring to the vehicle. Install the water pump and torque the retaining bolts EVENLY to 11 ft. lbs.
  2.  
  3. Lower the engine if necessary, and connect the coolant hose to the water pump. Reconnect the engine coolant inlet pipe to the vehicle and secure to hose with clamp and secure to block with 2 nuts. Tighten the engine coolant inlet pipe nuts to 11 ft. lbs.
  4.  
  5. Connect the electrical connector for the coolant temperature sending unit.
  6.  
  7. Install the oil guide tube and torque the retaining bolt to 84 inch lbs. Install the oil level indicator to the guide tube.
  8.  
  9. Install the radiator fan assembly, if necessary.
  10.  
  11. If equipped with power steering, raise and safely support the vehicle. Install the front transaxle mount. Torque the through bolt nut to 64 ft. lbs. and 2 mount nuts to 47 ft. lbs.
  12.  
  13. Lower the vehicle (if necessary) and install the No. 3 (upper) and No. 2 (middle) timing belt covers.
  14.  
  15. Support the engine using suitable equipment. Install the right engine mount and insulator.
  16.  
  17. Remove all engine lifting equipment.
  18.  
  19. Install and adjust all drive belts.
  20.  
  21. Reconnect the negative battery cable. Fill the cooling system. Start the engine and check for coolant leaks.
  22.  

 
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