HHR 2006-2008

Removal & Installation

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2.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
    NOTE
    A drain has been provided at the bottom of the water pump for engine block coolant drainage.

  4.  
  5. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  6.  
  7. Lower the vehicle.
  8.  
  9. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  10.  
  11. Remove the ECT sensor, if necessary.
  12.  
  13. Reposition the surge tank outlet hose clamp at the thermostat housing.

    Click image to see an enlarged view

    Fig. Thermostat housing

  14.  
  15. Remove the surge tank outlet hose from the thermostat housing.
  16.  
  17. Reposition the radiator outlet hose clamp at the thermostat housing.
  18.  
  19. Remove the radiator outlet hose from the thermostat housing.
  20.  
  21. Remove the exhaust heat shield bolts.
  22.  
  23. Remove the exhaust heat shield.
  24.  
  25. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  26.  
  27. Disconnect the heater inlet and outlet hoses from the thermostat housing pipes.
  28.  
  29. Remove the thermostat housing bolts.
    NOTE
    Twist the water transfer pipe while pulling in order to remove it from the water pump.

  30.  
  31. Remove the thermostat housing from the vehicle.
  32.  
  33. Remove the water transfer pipe from the thermostat housing, if necessary.
  34.  
  35. Remove and discard the water transfer pipe O-ring seals, if necessary.
  36.  
  37. Remove the thermostat housing cover bolts and cover, if necessary.
  38.  
  39. Remove the thermostat, if necessary.
  40.  
  41. Remove and discard the thermostat housing O-ring seal, if necessary.
  42.  
  43. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

    Click image to see an enlarged view

    Fig. Water pump access cover

  44.  
  45. Remove the water pump access plate from the front cover.
  46.  
  47. Remove the right hand fender liner.
    NOTE
    A drain plug has been provided at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump.

  48.  
  49. Drain the coolant from the water pump using the plug at the bottom of the pump.
    NOTE
    The water pump holding tool supports the sprocket and chain during water pump service. The tool must be used or the balance shaft must be re-timed.



    Click image to see an enlarged view

    Fig. Water pump holding tool

  50.  
  51. Install water pump holding tool J 43651 into position.
  52.  
  53. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  54.  
  55. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  56.  
  57. Remove the 3 inner water pump sprocket to water pump bolts.
    NOTE
    Be sure to remove both water pump bolts from the front of the engine block.

  58.  
  59. Remove the 2 water pump bolts.

    Click image to see an enlarged view

    Fig. Front water pump bolts

  60.  
  61. Remove the rear 2 water pump bolts.

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    Fig. Rear water pump bolts

  62.  
  63. Remove the water pump.
  64.  
  65. Remove and discard the water pump O-ring seal.
  66.  

To install:


NOTE
Prior to installing the water pump, read the entire procedure. This will help avoid balance shaft chain re-timing and ensure proper sealing.

  1. Install a NEW water pump O-ring seal.
    NOTE
    A guide pin can be created to aid in water pump alignment. Use an M 6 m x 6 mm stud. Thread the pin into the water pump sprocket.



    Click image to see an enlarged view

    Fig. Guide pin installation

  2.  
  3. Using the guide pin, align the pin with the water pump holding tool.
  4.  
  5. Position the water pump against the engine block and hand tighten the water pump bolts.
  6.  
  7. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten the bolts to 25 Nm (18 ft. lbs.).
  8.  
  9. Tighten the water pump sprocket bolts last. Tighten the bolts to 89 inch. lbs. (10 Nm).
  10.  
  11. Remove the tool.
  12.  
  13. Install the water pump access plate and bolts. Tighten the bolts to 89 inch. lbs. (10 Nm).
  14.  
  15. Install the right hand fender liner.
  16.  
  17. Install a NEW thermostat housing cover O-ring seal into the recess groove.
  18.  
  19. Install the thermostat, if necessary.
  20.  
  21. Install the thermostat housing cover bolts, if necessary. Tighten the bolts to 89 inch. lbs. (10 Nm).
  22.  
  23. Install a NEW thermostat housing to engine gasket onto the thermostat housing.
  24.  
  25. Load the thermostat housing assembly into position while the vehicle is lowered.
  26.  
  27. Raise and support the vehicle.
    NOTE
    The water feed pipe seals can be lightly lubricated with coolant to aid during installation.

  28.  
  29. Install NEW O-ring seals onto the water feed pipe.
    NOTE
    Lubricate the O-rings with coolant ONLY.

  30.  
  31. Install the water feed pipe into the thermostat housing aligning locator tab.
  32.  
  33. Align the water pipe to water pump.
  34.  
  35. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  36.  
  37. Lower the vehicle.
  38.  
  39. Position the thermostat housing against the engine.
  40.  
  41. Install the thermostat housing bolts. Tighten the bolts to 89 inch. lbs. (10 Nm).
  42.  
  43. Connect the heater inlet and outlet hoses to the thermostat housing pipes.
  44.  
  45. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
  46.  
  47. Install the exhaust heat shield.
  48.  
  49. Install the exhaust heat shield bolts. Tighten the bolts to 17 ft. lbs. (23 Nm).
  50.  
  51. Install the radiator outlet hose to the thermostat housing.
  52.  
  53. Position the radiator outlet hose clamp at the thermostat housing.
  54.  
  55. Install the surge tank outlet hose to the thermostat housing.
  56.  
  57. Position the surge tank outlet hose clamp at the thermostat housing.
  58.  
  59. Install the ECT sensor, if necessary.
  60.  
  61. Connect the ECT sensor electrical connector.
    NOTE
    The vehicle must be level when filling the cooling system.

  62.  
  63. Verify the drain valves at the radiator and water pump are closed.
  64.  
  65. Fill the cooling system.
  66.  
  67. Lower the vehicle.
  68.  
  69. Check for any leaks.
  70.  

2.2L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If equipped with an automatic transaxle, remove the exhaust manifold.
  4.  
  5. Drain the cooling system.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Remove the right front tire and wheel.
  10.  
  11. Remove the front fender liner.

    Click image to see an enlarged view

    Fig. Water pump access cover-2.2L engine

  12.  
  13. Remove the access plate on the water pump sprocket from the timing cover.
  14.  
  15. Install tool J 43651, or equivalent, on the water pump sprocket.
    NOTE
    Use the access plate bolts to secure the tool to the engine front cover.

  16.  
  17. Remove the bolts that secure the sprocket to the water pump.

    Click image to see an enlarged view

    Fig. Remove these 2 water pump bolts first-2.2L engine

  18.  
  19. Remove the bolt (1) that secures the water pump to the engine block.
  20.  
  21. Remove the bolt (2) that secures the engine water pump to the front cover.
  22.  
  23. Remove the feed pipe that joins the thermostat housing to the water pump.
  24.  
  25. Remove the 2 bolts that secure the water pump to the engine block.

    Click image to see an enlarged view

    Fig. Water pump removal-2.2L engine

  26.  
  27. Remove the water pump.
  28.  

To install:

  1. Use a threaded stud in the hub to align the hub to the water pump sprocket.
  2.  
  3. Install the water pump.
  4.  
  5. Install the 2 bolts that secure the water pump to the engine block. Tighten the bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the feed pipe that joins the thermostat housing to the water pump.
  8.  
  9. Install the engine front cover bolt and the bolt that secures the water pump to the engine block. Tighten the bolts to 15 ft. lbs. (20 Nm).
  10.  
  11. Install 2 of the bolts that secure the water pump sprocket to the water pump.
  12.  
  13. Remove the threaded stud.
  14.  
  15. Install the last bolt. Tighten the bolts to 62 inch lbs. (7 Nm).
  16.  
  17. Install the access plate on the water pump sprocket to the timing cover.
  18.  
  19. Install the bolts that secure the access plate to the timing cover. Tighten the bolts to 18 inch lbs. (10 Nm).
  20.  
  21. Install the front fender liner.
  22.  
  23. Install the right front tire and wheel.
  24.  
  25. If equipped with an automatic transaxle, install the exhaust manifold.
  26.  
  27. Fill the cooling system.
  28.  

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Removing the engine coolant temperature sensor -2.4L engine



    Click image to see an enlarged view

    Fig. Removing the thermostat housing and water feed pipe from the water pump cover-2.4L engine

  4.  
  5. Remove the engine coolant temperature sensor.
  6.  
  7. Remove the thermostat and water feed pipe retaining bolts.
    NOTE
    Twist the water feed pipe while pulling to remove it from the water pump cover.

  8.  
  9. Remove the thermostat housing and water feed pipe from the water pump cover.
  10.  
  11. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
  12.  
  13. Remove the water pump assembly.

    Click image to see an enlarged view

    Fig. Removing the water pump bolts and water pump assembly-2.4L engine

  14.  

To install:


WARNING
Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

  1. Install the water pump assembly.
  2.  
  3. Install the water pump bolts. Finger tighten the bolts.
  4.  
  5. Tighten the water pump bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Apply sealant GM P/N 12346004 or equivalent to the water pump drain plug.
  8.  
  9. Install the water pump drain plug, if necessary. Tighten the water pump drain plug to 15 ft. lbs. (20 Nm).
  10.  
  11. Install the water feed tube.
  12.  
  13. Lubricate the feed tube O-ring with clean antifreeze.
  14.  
  15. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
  16.  
  17. Install the thermostat housing to block bolts and stud. Tighten the bolts to 89 inch lbs. (10 Nm).
  18.  
  19. Install the engine coolant temperature sensor by hand.
  20.  
  21. Tighten the engine coolant temperature sensor. Tighten the engine coolant temperature sensor to 15 ft. lbs. (20 Nm).
  22.  
  23. Fill the cooling system.
  24.  

 
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