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    1958 Mercury Monterey 6.3L 4BL 8cyl

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    405 N COLLEGE ST
    (479) 443-4043

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    See Details

    Malibu 2001-2005

    Removal & Installation

    Print

    2.2L Engine



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
      NOTE
      A drain plug is located at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump.

    4.  
    5. Remove or disconnect the following:
      NOTE
      Leave the coolant hoses connected.



      Negative battery cable
       
      Thermostat housing pipe-to-cylinder head bolt near the front of the engine
       
      Exhaust manifold heat shield
       
      Water pump access plate
       
      Coolant temperature sensor
       
      Thermostat housing
       



      Coolant inlet hose
       

    6.  
    7. Install special tool J 43651 to prevent movement of the camshaft sprocket and timing chain.
    8.  
    9. Remove 3 inner sprocket-to-water pump mounting bolts.
    10.  
    11. Remove water pump assembly bolts
    12.  
    13. Remove the water pump.
    14.  

    To install:

    1. Install or connect the following:

      Water pump with a new gasket. Tighten the assembly bolts to 18 ft. lbs. (25 Nm).
       
      Sprocket-to-water pump bolts and tighten to 89 inch lbs. (10 Nm)
       

    2.  
    3. Remove special tool J 43651.
    4.  
    5. Install or connect the following:

      Coolant inlet hose with new gasket
       
      Thermostat housing and tighten to 89 inch lbs. (10 Nm)
       
      Coolant temperature sensor
       
      Water pump access plate
       
      Thermostat housing pipe-to-cylinder head bolt to 71 inch lbs. (8 Nm)
       
      Exhaust manifold heat shield
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system to the correct level.
    8.  
    9. Start the engine and check for leaks.
    10.  

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
      NOTE
      A drain plug is located at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump.

    4.  
    5. Remove the thermostat housing.
    6.  
    7. Remove the coolant heater.
    8.  
    9. Remove the water pump access plate from the front cover.
      WARNING
      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 access plate removal

    10.  
    11. Install the J 43651 water pump holding tool into position.
    12.  
    13. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
    14.  
    15. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
    16.  
    17. Remove the 3 inner water pump sprocket to water pump bolts through the holes in the water pump holding tool.
    18.  
    19. Remove the 2 water pump bolts.
      NOTE
      Be sure to remove both water pump bolts from the front of the engine block.



      Click image to see an enlarged view

      Fig. Front water pump mounting bolts shown

    20.  
    21. Remove the rear 2 water pump bolts.

      Click image to see an enlarged view

      Fig. Rear water pump mounting bolts shown

    22.  
    23. Remove the engine wiring harness clip nut from the water pump stud.
    24.  
    25. Remove the engine wring harness clip from the stud.
    26.  
    27. Remove the water pump.

      Click image to see an enlarged view

      Fig. Water pump removal

    28.  

    To install:

    1. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.
    2.  
    3. Install the water pump drain plug and tighten to 15 ft. lbs. (20 Nm).
      NOTE
      A guide pin can be created to aid in water pump alignment. Use a M6 m x 6 mm stud.

    4.  
    5. Using the J 25025-5 or a guide pin, align the pin with the water pump holding tool.
    6.  
    7. Position the water pump against the engine block and hand tighten the water pump bolts.
    8.  
    9. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt.

      Click image to see an enlarged view

      Fig. Water pump alignment using the J 25025-5 guide

    10.  
    11. Tighten the bolts to 18 ft. lbs. (25 Nm).
    12.  
    13. Tighten the water pump sprocket bolts last. Tighten the bolts to 89 inch. lbs. (10 Nm).
    14.  
    15. Remove the J 43651 water pump holding tool.
    16.  
    17. Install the coolant heater.
    18.  
    19. Install the water pump access plate and bolts and tighten to 89 inch. lbs. (10 Nm).
    20.  
    21. Install the thermostat housing.
    22.  

    3.1L And 3.5L Engine



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Water pump pulley bolts, loosen
       
      Accessory drive belt
       
      Water pump pulley
       
      Water pump bolts, pump and gasket
       

    6.  

    To install:

    Click image to see an enlarged view

    Fig. Exploded view of the water pump mounting

    1. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area.
    2.  
    3. Install or connect the following:

      Water pump with a new gasket. Torque the bolts to 89 inch lbs. (10 Nm).
       
      Water pump pulley and finger-tighten the bolts
       
      Accessory drive belt
       
      Water pump pulley bolts and torque to 18 ft. lbs. (24 Nm)
       
      Negative battery cable
       

    4.  
    5. Refill and bleed the cooling system.
    6.  
    7. Operate the engine and check for leaks.
    8.  

    3.5L (LX9) Engine



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Water pump pulley bolts, loosen
       
      Accessory drive belt
       
      Water pump pulley
       
      Water pump bolts, pump and gasket
       

    6.  

    To install:

    Click image to see an enlarged view

    Fig. Exploded view of water pump mounting 3.5L (LX9) engine

    1. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area.
    2.  
    3. Install or connect the following:

      Water pump with a new gasket. Tighten the bolts to 89 inch lbs. (10 Nm).
       
      Water pump pulley and finger-tighten the bolts
       
      Accessory drive belt
       
      Water pump pulley bolts and torque to 18 ft. lbs. (24 Nm)
       
      Negative battery cable
       

    4.  
    5. Refill and bleed the cooling system.
    6.  
    7. Operate the engine and check for leaks.
    8.  

    3.5L (LZ4) & 3.9L (LZ9) Engines



    1. Drain the cooling system.
    2.  
    3. Loosen the water pump pulley bolts.
    4.  
    5. Remove the drive belt.
    6.  
    7. Remove the water pump bolts.
    8.  
    9. Remove the water pump and gasket.
    10.  
    11. Clean the water pump mating surfaces.

      Click image to see an enlarged view

      Fig. Exploded view of water pump mounting 3.5L (LZ4) engine

    12.  

    To install:

    1. Position a NEW water pump gasket and the water pump to the engine front cover.
    2.  
    3. Install the water pump bolts and tighten the bolts to 89 inch lbs. (10 Nm).
    4.  
    5. Install the water pump pulley and bolts
    6.  
    7. Install the drive belt.
    8.  
    9. Tighten water pump pulley bolts to 18 ft. lbs. (25 Nm).
    10.  
    11. Fill and bleed the cooling system.
    12.  
    13. Inspect for leaks.
    14.  

     
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