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    1998 Saab 9000 CSE 2.3L Turbo DOHC 4cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

    Water Pump

    Print

    REMOVAL & INSTALLATION



    2.0L Engine

    See Figure 1

    1. Disconnect the negative battery cable.
    2.  
    3. Properly drain the engine coolant into a clean container for reuse.
    4.  
    5. Remove the timing belt.
    6.  
    7. Unfasten and remove the timing belt rear protective covers.
    8.  
    9. Detach the hose from the water pump.
    10.  
    11. Unfasten the water pump attaching bolts, then remove the water pump and seal ring.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 1: View of the water pump mounting and O-ring-2.0L engine

    To install:
    1. Thoroughly clean and dry the mounting surfaces, bolts and bolt holes.
    2.  
    3. Using a new sealing ring, install the water pump to the engine and hand-tighten the retaining bolts.
    4.  
    5. Attach the hose to the water pump.
    6.  
    7. Fasten the timing belt rear protective covers, then install the timing belt and properly adjust the tension.
    8.  
    9. Tighten the water pump bolts to 18 ft. lbs. (24 Nm).
    10.  
    11. Install the timing belt cover and related parts.
    12.  
    13. Connect the negative battery cable.
    14.  
    15. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks and top-off the coolant.
    16.  

    2.3L Engine

    See Figure 2

    1. Disconnect the negative battery cable
    2.  
    3. Detach the oxygen sensor connector.
    4.  
    5. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for more complete coolant drain.
    6.  
    7. Remove upper and lower exhaust manifold heat shields.
    8.  
    9. Remove the bolt that attaches the exhaust manifold brace to the manifold.
    10.  
    11. Break loose the manifold to exhaust pipe spring loaded bolts using a 13mm box wrench.
    12.  
    13. Raise and safely support the vehicle.
    14.  

    It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.

    1. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
      1. Unscrew either bolt clockwise 4 turns.
      2.  
      3. Remove the other bolt.
      4.  
      5. Remove the first bolt.
      6.  

    2.  
    3. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
    4.  
    5. Remove the radiator outlet pipe from the oil pan and transaxle. If equipped with a manual transaxle, remove the exhaust manifold brace. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump.
    6.  
    7. Carefully lower the vehicle.
    8.  
    9. Remove the exhaust manifold, seals and gaskets.
    10.  
    11. Loosen and reposition the rear engine mount and bracket for clearance, as required.
    12.  
    13. Remove the water pump mounting bolts and nuts. Remove the water pump and cover assembly, then separate the two pieces.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 2: View of the water (coolant) pump mounting-1994 2.3L engine shown

    To install:
    1. Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
    2.  
    3. Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
    4.  
    5. Lubricate the radiator outlet pipe O-ring with antifreeze and install to the water pump with the bolts finger-tight.
    6.  
    7. With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
      1. Pump assembly-to-chain housing nuts-19 ft. lbs. (26 Nm).
      2.  
      3. Pump cover-to-pump assembly-106 inch lbs. (12 Nm).
      4.  
      5. Cover-to-block, bottom bolt first-19 ft. lbs. (26 Nm).
      6.  
      7. Radiator outlet pipe assembly to pump cover-125 inch lbs. (14 Nm).
      8.  

    8.  
    9. Install the exhaust manifold.
    10.  
    11. Raise and safely support the vehicle.
    12.  
    13. Install the exhaust pipe flange bolts evenly and gradually to avoid binding.
    14.  
    15. Connect the radiator outlet pipe to the transaxle and oil pan. Install the exhaust manifold brace, if removed. Lower the vehicle.
    16.  
    17. Fasten the bolt that attaches the exhaust manifold brace to the manifold.
    18.  
    19. Install the heat shields.
    20.  
    21. Attach the oxygen sensor connector.
    22.  
    23. Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
    24.  
    25. Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine off.
    26.  
    27. Once the vehicle has cooled, recheck the coolant level.
    28.  

    2.4L Engine

    See Figure 3

    1. Disconnect the negative battery cable.
    2.  
    3. Drain and recycle the engine coolant.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 3: Exploded view of the water pump and mounting on the engine-2.4L engine

    1. Disconnect the oxygen sensor wiring.
    2.  
    3. Remove the upper exhaust manifold heat shield.
    4.  
    5. Raise and safely support the front end of the vehicle securely on jackstands.
    6.  
    7. Remove the exhaust manifold brace bolt.
    8.  
    9. Unbolt and remove the lower exhaust manifold heat shield.
    10.  
    11. Break loose the manifold-to-exhaust pipe spring loaded nuts.
    12.  
    13. Unbolt the radiator outlet pipe assembly from the water pump cover.
    14.  
    15. Disconnect the exhaust pipe from the manifold.
    16.  
    17. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
    18.  

    Do not rotate the flex coupling more than 4°. this could damage the component.

    1. Separate the radiator outlet pipe from the oil pan and transaxle.
      1. On manual transaxle, remove the exhaust manifold brace.
      2.  

    2.  
    3. Next, leave the lower radiator hose attached and pull down on the outlet pipe to detach it from the water pump. Allow the outlet pipe to hang.
    4.  
    5. Lower the vehicle.
    6.  
    7. Remove the exhaust manifold-to-cylinder head nuts.
    8.  
    9. Extract the manifold, seals and gaskets.
    10.  
    11. Remove the timing chain cover. Refer to the procedure later on in this section.
    12.  
    13. Remove the timing chain tensioner. Refer to Timing Chain removal later in this section.
    14.  
    15. Unbolt the water pump from the cylinder block.
    16.  
    17. Extract the pump assembly-to-timing chain housing nuts.
    18.  
    19. Remove the water pump and cover assembly.
    20.  
    21. Separate the pump from the cover.
    22.  
    23. Clean all mating surfaces of gaskets and sealant materials.
    24.  

    To install:

    Prior to installing the water pump, read the entire procedure. Pay special attention to the tightening sequence to avoid component damage and ensure a proper seal.

    1. Attach the water pump to the cover and hand-tighten the components.
    2.  
    3. Lubricate the splines of the water pump drive with chassis grease or equivalent, then install the pump and cover assembly. Hand tighten the cover-to-block bolts.
    4.  
    5. Install the pump-to-chain housing nuts and hand-tighten.
    6.  
    7. Lubricate the O-ring on the radiator outlet pipe with an anti-freeze solution and slide the pipe into the water pump cover, install and hand-tighten the bolts.
    8.  
    9. With the specified gaps, tighten in sequence as follows:
      1. Pump assembly-to-chain housing nuts
      2.  
      3. Pump cover-to-pump assembly
      4.  
      5. Cover-to-block, bottom bolt first
      6.  
      7. Radiator outlet pipe assembly-to-cover
      8.  

    10.  
    11. Install the exhaust manifold using new gaskets.
    12.  
    13. Install the manifold-to-cylinder head nuts, follow the tightening sequence and tighten to specifications.
    14.  
    15. Raise and support the front of the vehicle.
    16.  
    17. Index the exhaust manifold-to-exhaust pipe flange bolts.
      1. Turn bolt bolts in evenly to avoid cocking the exhaust pipe and binding the bolts. Turn the bolts in until they are fully seated.
      2.  

    18.  
    19. Install and secure the radiator outlet pipe to the transaxle and oil pan.
    20.  

    On manual transaxles, install the exhaust manifold brace.

    1. Install the timing chain tensioner and chain cover.
    2.  
    3. Attach the lower heat shield.
    4.  
    5. Lower the vehicle.
    6.  
    7. Attach the exhaust manifold brace. Tighten the manifold-to-exhaust pipe nuts to specification.
    8.  
    9. Attach and secure the upper heat shield.
    10.  
    11. Connect the oxygen sensor wiring.
    12.  
    13. Fill the radiator with coolant water mixture until it reaches the heater hose coolant outlet, then install the hose and continue to fill. This will assist with the complete cylinder block fill.
    14.  
    15. Connect the negative battery cable.
    16.  
    17. Start the engine and top off the cooling system and check for leaks.
    18.  

    2.5L Engine

    See Figures 4 and 5

    1. Disconnect the negative battery cable.
    2.  
    3. Properly drain the engine coolant into a suitable container.
    4.  
    5. Remove the drive belts.
    6.  
    7. If necessary for access, remove the alternator and A/C compressor.
    8.  
    9. Unfasten the water pump front cover assembly mounting bolts, then remove the water pump front cover assembly.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 4: View of the water pump mounting-2.5L engine

    To install:
    1. If installing a new pump, transfer the water pump pulley to the new pump using installer tool J25034-B, J29785-A or equivalent.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 5: If installing a new water pump, transfer the pulley from the old pump using the proper tool

    1. Thoroughly clean and dry the mounting surfaces, bolts and bolt holes. Place a 1 /8 inch (3mm) bead of RTV sealant on the pump's sealing surface.
    2.  
    3. Install the pump to the engine, coating the bolt threads with sealant as they are installed. Tighten the bolts to 25 ft. lbs. (34 Nm).
    4.  
    5. If removed, install the alternator and/or air conditioning compressor.
    6.  
    7. Install and adjust the drive belts. Refer to Routine Maintenance .
    8.  
    9. Connect the negative battery cable.
    10.  
    11. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks. Top off coolant level if necessary.
    12.  

    3.0L Engine

    See Figure 6

    1. Disconnect the negative battery cable.
    2.  
    3. Properly drain the cooling system into a suitable container.
    4.  
    5. Remove the drive belt.
    6.  
    7. Detach the coolant hoses at the water pump.
    8.  
    9. Unfasten the water pump pulley bolts (the long bolt can be removed through the access hole in the body side rail), then remove the pulley.
    10.  
    11. Unfasten the water pump mounting bolts, then remove the pulley.
    12.  
    13. Thoroughly clean and dry all gasket mating surfaces.
    14.  

    To install:


    Click image to see an enlarged view

    Fig. Fig. 6: Water pump mounting and bolt tightening specifications-3.0L engine shown

    1. Using a new gasket, install the water pump on the engine. Tighten the mounting bolts to the specifications.
    2.  
    3. Install the water pump pulley, then tighten the retaining bolts to 10 ft. lbs. (13 Nm).
    4.  
    5. Attach the coolant hoses to the pump.
    6.  
    7. Install the drive belt.
    8.  
    9. Fill the cooling system to the proper level with the correct type of coolant.
    10.  
    11. Connect the negative battery cable, then start the engine. Let the engine run until it reaches normal operating temperature, then check for leaks and coolant level. Add coolant, if necessary, then turn the engine off.
    12.  

    3.1L Engine

    See Figure 7

    1. Disconnect the negative battery cable.
    2.  
    3. Properly drain the cooling system into a suitable container.
    4.  
    5. Loosen, but do not remove, the water pump pulley bolts.
    6.  
    7. Remove the serpentine belt.
    8.  
    9. Unfasten the water pump pulley bolts, then remove the pulley.
    10.  
    11. Remove the five water pump mounting bolts, then remove the water pump.
    12.  

    To install:


    Click image to see an enlarged view

    Fig. Fig. 7: View of the water pump mounting-3.1L engine shown

    1. Clean all the gasket surfaces completely.
    2.  
    3. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area, then install the gasket onto the water pump.
    4.  
    5. Position the water pump on the engine, then tighten the water pump mounting bolts to 89 inch lbs. (10 Nm).
    6.  
    7. Install the water pump pulley and finger-tighten the pulley bolts.
    8.  
    9. Install the serpentine belt.
    10.  
    11. Tighten the water pump pulley bolts to 18 ft. lbs. (25 Nm).
    12.  
    13. Fill the cooling system.
    14.  
    15. Connect the negative battery cable, then start the engine. Let the engine run until it reaches normal operating temperature, then check for leaks and coolant level. Add coolant, if necessary, then turn the engine off.
    16.  

    3.3L Engine

    See Figure 8

    1. Disconnect the negative battery cable.
    2.  
    3. Properly drain the engine coolant into a suitable container.
    4.  
    5. Support the engine using J 28467-A or equivalent engine support fixture.
    6.  
    7. Remove the right engine mount.
    8.  
    9. Loosen, but do not remove, the water pump pulley bolts.
    10.  
    11. Remove the serpentine belt.
    12.  
    13. Unfasten and remove the idler pulley, then remove the engine brace.
    14.  
    15. Unfasten the water pump pulley bolts and remove the pump with the pulley attached. Separate the pump from the pulley.
    16.  
    17. Thoroughly clean and dry the mounting surfaces, bolts and bolt holes.
    18.  



    Click image to see an enlarged view

    Fig. Fig. 8: View of the water pump mounting and bolt tightening specifications

    To install:
    1. Attach the water pump to the pulley, tighten the pump-to-pulley bolts to 10 ft. lbs. (13 Nm), then install as an assembly. Install and hand-tighten the pulley bolts.
    2.  
    3. Install the engine brace and idler pulley.
    4.  
    5. Install the serpentine belt.
    6.  
    7. Tighten the water pump pulley bolts to 22 ft. lbs. (30 Nm).
    8.  
    9. Install the right engine mount.
    10.  
    11. Remove the engine support fixture.
    12.  
    13. Fill the system with coolant.
    14.  
    15. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator and recovery tank to the correct level.
    16.  
    17. Turn the engine off. Once the vehicle has cooled, recheck the coolant level and add if necessary.
    18.  

     
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