Water Pump Assembly - L61: Installation

WARNING: This page is about a different car, the 2002 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

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

Install new water pump assembly seal.

Fig 1: Installing New Water Pump Assembly Seal
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: A guide pin can be created to aid in water pump alignment. Use a M6 m x 6 mm stud. Thread the pin into the water pump sprocket.
Using guide pin, align pin with hole in water pump holding tool.
Position the water pump assembly against the engine block and hand tighten the water pump bolts.
Install inner water pump sprocket bolts. After two are snug, remove the guide pin and install the third bolt.
Torque:

Water Pump Bolts - L61: 25 N.m (18 ft-lbs)

Fig 2: Installing Inner Water Pump Sprocket Bolts
Courtesy of GENERAL MOTORS CORP.
Tighten water pump bolts.
Torque:

Water Pump Sprocket-to-Water Pump Bolts - L61: 10 N.m (89 in-lbs)
Remove water pump holding tool J43651.
Install water pump access plate and bolts.
Torque:

Water Pump Access Bolts-to-Front Cover - L61: 10 N.m (89 in-lbs)

IMPORTANT: The water feed pipe seals can be lightly lubricated with silicone gel to aid in assembly.

Fig 3: Installing Water Pump Access Plate And Bolts
Courtesy of GENERAL MOTORS CORP.
Install new O-seal on water feed pipe.
Install thermostat housing to block seal onto thermostat housing (if damaged).
Install water feed pipe into water pump assembly.
Align the water feed pipe to thermostat housing assembly.
Seat water feed O-seal by pushing and twisting toward water pump. Take care not to tear or damage O-ring.
Water feed pipe has a locating tab to assure proper alignment.
Position thermostat housing against engine. Be sure that thermostat housing pipe is properly positioned against the support bracket near the front of engine.
Install thermostat housing to block bolts.
Torque:

Thermostat Housing-to-Block Bolts - L61: 10 N.m. (89 in-lbs)

Fig 4: Installing Thermostat Housing To Block Bolts
Courtesy of GENERAL MOTORS CORP.
Connect electrical connector to coolant temperature sensor.
Install right hand inner splash shield and push pins.
Install right hand tire assembly and wheel nuts.
Torque:

Wheel Nuts: 125 N.m (92 ft-lbs)
Lower vehicle.
Install thermostat pipe bracket to cylinder head bolt.
Torque:

Thermostat Pipe Bracket-to-Cylinder Head Bolt - L61: 8 N.m (71 in-lbs)

Fig 5: Connecting Electrical Connector To Coolant Temperature Sensor
Courtesy of GENERAL MOTORS CORP.
Install exhaust manifold heat shield.
Install exhaust manifold heat shield bolts.
Torque:

Exhaust Manifold Heat Shield Bolts - L61: 25 N.m (18 ft-lbs)

Fig 6: Installing Exhaust Manifold Heat Shield Bolts
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Vehicle must be level when filling cooling system.
Verify drain valve at radiator and water pump are closed.
Fill engine coolant.
Verify repair and inspect for any leaks.

Fig 7: Installing Coolant Reservoir Cap
Courtesy of GENERAL MOTORS CORP.