Water Pump Removal Problem.

I'm trying to change the timing belt on my 2004 Chevy Aveo and I'm having problems with the water pump. I've removed the 3 screws that keep it in place and I also removed the the tensioner pulley, idler pulley, and the camshaft wheels to remove the inner cover; the water pump simply refuses to come out. I tried turning it with the 41mm water pump wrench and nothing. I tried WD-40 and that didn't work. I tried pulling it by hand and nothing. Is there anything else I can try to remove the water pump?

the Oring is probably seized in there pretty good. your going to probably have to turn it back and forth with the 41mm, and pry out on it at the same time until you wiggle or work it out of there.

I would use the pump drive as a pull. Put a long screwdriver under it, the end on a block of wood, and pull on the handle. Instead of WD-40 shoot some purple magic (alkaline detergent), that can make the o-ring slippery

I tried the pulling and turning technique but still nothing, its on there like cement. I haven't heard of Purple Magic but ill give it a try and see if that helps.

Aaaaaand nothing. Water pump is still stuck on; have no clue what to do.

Maybe it's time to take some pictures. We might be able to see something that you may have missed.


At least does it rotate?

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Originally Posted by xintersecty

Maybe it's time to take some pictures. We might be able to see something that you may have missed.


At least does it rotate?

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The only thing that rotates is the pump drive wheel. When I try to move the water pump body with the water pump wrench it doesn't turn. I'll be uploading some pictures in few moments.

Here are a few pictures of the water pump I'm trying to take off. It's still on there pretty good.

Attachment 9264Attachment 9265Attachment 9266Attachment 9267

this might sound a little brutal, but get a soft faced hammer or Rubber mallet, and tap on the Water Pump Sprocket until the pump drops out of the Volute.

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Originally Posted by 2010AveoLT

this might sound a little brutal, but get a soft faced hammer or Rubber mallet, and tap on the Water Pump Sprocket until the pump drops out of the Volute.

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I would agree, the other thing you can do is get a big flat blade screw driver and drive in that grove upper right. The other option is to ice chill the pump and hope that allow will shrink faster than the steel.

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Originally Posted by xintersecty

I would agree, the other thing you can do is get a big flat blade screw driver and drive in that grove upper right. The other option is to ice chill the pump and hope that allow will shrink faster than the steel.

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I wouldn't do that for the simple fact that you could damage the mating surface that the o-ring uses to seal the pump to the block.

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Originally Posted by 2010AveoLT

this might sound a little brutal, but get a soft faced hammer or Rubber mallet, and tap on the Water Pump Sprocket until the pump drops out of the Volute.

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Before my aveo I used to have a "Chevy corsa pick up 1999", it uses the same water pump as aveos. I literaly had to chisel it to pieces bit by bit as it was really stuck in there! luckily no damage to engine block occured! I didnt replace the water pump when I should have.

well, I got fed up with trying to hammer it and pull it off so I decided to use a drill to drill a hole in the middle and try breaking it piece by piece. So far I'm getting some very good progress; I've bought a dremel tool to help cut the pump into pieces.

Yep... thats more or less the way I had to do it. It takes a couple of hours but in the end it will give in. All I recommend is patience as if you get angry (and you will) you could damage the engine block or other parts.

Finally got the corroded P.O.S. out.

Attachment 9306Attachment 9307Attachment 9308Attachment 9309

WOW, that Pump was Virtually RUSTED to the Block! its a good thing you're replacing it then!

Congratulations! I am impressed that it adhered to the block. I would defiantly flush your water system. And take some light sand paper to the block to make sure that mating surface is clean.

[QUOTE=chonzerfool;193266]Finally got the corroded P.O.S. out.

Great pics! I think Ive got some old pics somewhere. Will have a look for em.

Well, ain't that funny? After one problem is done, along comes another one. I've replaced the water pump, put on a new timing belt, and did all the aligning correctly. Placed everything in order; double and triple checked that all the connections were on and made sure nothing was loose, and finally added new coolant. Just as I was about to turn the engine over, Nothing. Car won't turn on. I crank it for 5 seconds and it doesn't want to turn on. I can hear the fuel pump priming, but it wont turn on. I've had the battery off for about 2 months since their was no point of using the car since It took forever to get the water pump off. Is there something I'm missing?

Thanks in advance.

usually after that long of a time out, the battery needs charging. Mine did when I did the shocks and body repairs. Just take it to auto shop and they are kind enough to charge it for you.

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Originally Posted by xintersecty

usually after that long of a time out, the battery needs charging. Mine did when I did the shocks and body repairs. Just take it to auto shop and they are kind enough to charge it for you.

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Or you can get a battery charger rather cheaply.

05 Aveo 1.6 smoking oil when I start goes away after it runs for a few min just did head gasket and timing and had all the valve seals replaced order head kit any common problems with oil ?

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Originally Posted by knucklebuster

05 Aveo 1.6 smoking oil when I start goes away after it runs for a few min just did head gasket and timing and had all the valve seals replaced order head kit any common problems with oil ?

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Did the timing belt break? If it did, it may have damaged the valve guides, rendering the valve seals useless.

The thing is I have the battery connected and all the lights, power locks, power windows work, but when I try cranking, the battery seems to die off. I tried jumping it and still wont turn on (it tries to crank but not turn on) I'm suspecting that the timing might be off or a sensor might be causing a problem.

Oh yeah, I think you maybe right. Do you get any lights and can read it with a scanner? I wonder as the engine turns over it's staling the starter. Did you remove the cam shaft gears? If so how do you know they are lined up correctly. The marking is on the gear but the gear has to be one correctly for that mark to mean anything.

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Originally Posted by chonzerfool

The thing is I have the battery connected and all the lights, power locks, power windows work, but when I try cranking, the battery seems to die off. I tried jumping it and still wont turn on (it tries to crank but not turn on) I'm suspecting that the timing might be off or a sensor might be causing a problem.

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Hello chonzerfool,

We see that you're having trouble starting your vehicle and we'd like to apologize for the inconvenience you've experienced. I'd be happy to look into this situation further and contact your dealership on your behalf for further assistance. If this is something of interest, please send your contact information, VIN, mileage and preferred dealership in a private message.

Thanks! :)

Jasmine F
Chevrolet Customer Care

Any updates? Want to see this to the end and that car on the road running

Took the battery to Walmart to have it replaced. They did a test and found that it had only 65 CCA instead of 600 CCA. They decided to charge the battery but in the end I ended up getting a replacement battery; the old one would not hold a charge (Dead). I Get home, redo all the steps and when it came time to crank the car, nothing still. I also noticed that the timing on the cam wheel is slightly off; the intake alignment is about a half a tooth off every time I put the belt on, and on top of that I also noticed that the belt seems to want to slip off, I put the proper tension every time but the belt looks like it want to fall off, could this be the tensioner failing?

The water pump is what really tensions the system. The three allen nuts around the pump need to be tighten (locked down) once the system has the right tension. The tensioner should indicate the proper tension.

So here is the right process. (don't be insulted if you already know this, we just don't know if you knew this.)
1) loosen the allen nuts around the water pump
2) rotate the water pump anti-clockwise to loosen tension, rotate the pump clockwise to increase tension.
3) The tension should move where the arrow moves towards to the notch.
4) Lock down the allen nuts

I found the intake cam is sprung and does not like to point as aligned. This is where a cam lock tool where come handy:
Universal Twin Cam Locking Timing Tool Kit for Petrol Diesel Engines Automotive | eBay

Sorry for the long wait. Long story short, sold the car; never got the car to turn on again.