How to: Water pump on 98 and similar Cavalier Z24

[PlanetDude]

K, having just gone through this job, I thought I`d post a how-to. Don`t take this as absolute advice, just as a guide.

First step. Drink a beer, pay a mechanic. I wish I had.

If you absolutely have to do this yourself, I`ll lay it out. Trust me, it sucks.
I suggest making diagrams, and using little labeled bags to hold parts.

1. Start with the exhaust manifold. Spray the nuts with penetrating oil.
2. Unbolt the pipe and mounting bracket from manifold. (Make sure you get this mounting bracket bolt. The job will be halted if you can`t get this bolt out.) Make sure you unplug the O2 sensor.
3. Work on the manifold bolts. I`m lucky, all 10 came out for me.
4. You`ll have to unhook the coolant line from the tank that runs over the manifold. Be careful not to break it off at the other end.
5. Remove the manifold and gasket.
6. On the side, remove the right front wheel.
7. Remove the drivebelt. 1/2 in wrench on the tensioner, rotate back towards the firewall and slip the belt off.
8. Remove the crank pulley bolt and pulley. (Important - don`t turn the engine backwards! Hold the pulley with a prybar - I held it and used impact to get the bolt off.)
9. Re-install the crankshaft pulley bolt.
10. Support the engine from below.
11. Remove the coolant tank.
12. Remove the motor mount and engine support bracket.
13. Remove the timing cover.
14. Turn the engine by hand to TDC and lock the cams in place with an 8mm bolt.
15. Remove the timing chain tensioner and guides.
16. Slip the timing chain off the water pump.
17. On the backside, unbolt the water pump and housing. There are 12 nuts and bolts in total.
18. Lift the entire assembly out.
19. On the bench, clean up all the gasket mating surfaces.
20. Install the water pump and gasket to the timing housing.
21. Install the thermostat and then the housing. Leave bolts finger tight until everything is in proper position, then tighten everything up.
22. Install the timing chain on the water pump.
23. Re-install the guides and use a new timing chain tensioner. Don`t forget to pull the bolts locking the cams.
24. If the crank seal in the timing cover is bad, change it.
25. Re-install the timing cover.
26. Remove the bolt and re-install the crank pulley.
27. Install the drivebelt.
28. Re-install the bracket and motor mount.
29. Installl the coolant tank.
30. At the rear of the motor, install the exhaust manifold and bolts/nuts.
31. Re-attach the pipe and plug the O2 sensor back in.
32. Fill with coolant.
33. Run and check for leaks. Burp the system of air and bleed.

I`d recommend a new thermostat, drivebelt, timing chain tensioner, and all gaskets.
I took the hood off, because I wound up on top of the motor working down a couple of times. I also changed the heater core lines because they were suspect, and I replaced all the clamps because I hate the pinch style, I used regualer threaded hose clamps.

If you have any questions or comments, please post. This isn`t a perfect description, but it`s a good guide, I think.

[fostmt]

Hey man im starting this project this weekend and i ran into my first problem. The exhaust manifold mounting bolt is either seized on there or it is just too tight. Do you have any tips on how to take it off. I am try to use a breaker bar but it at a bad angle and the universal isnt helping either. Right now im gonna try to shave down my breaker bar to get a better angle. Do you have anytips on how to get that bolt off? Also, do you have any tips for the whole project as well? Thanks

[Jmrec100]

Just a general helpful hint. Go to a marine hardware store and pick out a good spray for loosening rusted or stubborn bolts. Several years ago, I helped a friend replace the water pump on a Fiat. Man, why would they use four hundred metric bolts about the size of US #4 sized bolts. They snap like nothing. After snapping the heads off the first two, we went to the marine store nearby. Sprayed about the whole can on it and went for a boat ride. Sprayed again, had lunch. Then sprayed them again. And they came out so easyyyyyyyyyyyyy. We were amazed. We used a marine store because the salt environment of boats is alot more corrosive. Well, my thoughts for what it is worth.