HELP: 2009 Aveo " Variable Timing" 1.6 remote mount water pump removal

[Salto_Jorge]

HELP: 2009 Aveo Variable Timing 1.6 remote mount water pump removal

Reason for the repair is that the radiator hoses expanded, lower hose developed a crack and steam was coming out when wife was driving when it was about 20 degrees........ Either the head gasket is shot or the water pump went out.

Have already replaced the thermostat and housing and hose on the drivers side.

Mentioned Variable timing engine since my water pump is not driven off the timing belt.
Water pump is in front of the engine and driven off the serp belt.

Picture of new pump is attached

I have removed on the passenger side:

Front Tire
Inner Splash Shield
Air Cleaner
Head Light Assembly
Power Steering/ Water pump small belt (3/4 All bolt)
Main Serp Belt
Unbolted water pump pulley (#45 Torx) See Picture

Now the issue:

How do I remove the pulley from between the body and the water pump itself, it does not fit, See Picture.
Plus how can I get the pump out of the housing and past the sheet metal.

Is it necessary to remove the passenger side motor mounts and tilt the engine upwards to get things out ?

I have not seen any information on this.

I have a subscription to ALLDATAdiy.com, does not indicate if the engine needs to be tilted.


Dealer wants $580 US to do change the water pump.

Thank You
Salto

[EAD15]

From the 2009 Aveo Service Manual

Coolant Pump Replacement (1.4L LDT/1.6 LXV)

Special Tools

• EN-48356 Engine Fixture
• EN-49201 Water Pump Pulley Remover/Installer

Removal Procedure

• Drain the coolant. Refer to Cooling System Draining and Filling.
• Remove the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT .
• Remove the RH head lamp assembly. Refer to Headlamp Replacement (Notchback) or Headlamp Replacement (Hatchback) .Fig. 13: WaterPump Pulley Retaining Bolts
  Courtesy of GENERAL MOTORS CORP.
• Disconnect the A/C pipe retainer and move the A/C pipe.
• Remove the water pump pulley retaining bolts using EN-48356: fixture.
• Remove the accessory belt. Refer to DRIVE BELT REPLACEMENT .
• Fix the engine using EN-48356: fixture.
• Remove the engine mount.Fig. 14: WaterPump & Retaining Bolts
  Courtesy of GENERAL MOTORS CORP.
• Remove the water pump pulley.
• Remove the water pump retaining bolts (1).
• Remove the water pump (2).
• Remove the ring seal from the water pump.
• Inspect the water pump for cracks, leaks or abnormal noise.
• Cleaning the mating surfaces of the water pump and the cylinder head.

Installation Procedure

• Fig. 15: WaterPump & Retaining Bolts
  Courtesy of GENERAL MOTORS CORP.
• Install a new ring seal to the water pump.
  
  [TD="class: clsCautionLabel"]CAUTION:[/TD]
  
  
  

  Refer to Fastener Caution .

• Install the water pump (2) to the engine front cover.Tighten: Tighten the water pump retaining bolts (1) to 10 N.m (89 lb in).
• Install the water pump pulley.
• Install the engine mount.
• Install the accessory belt. Refer to DRIVE BELT REPLACEMENT .
• Connect the A/C pipe retainer and fix the A/C pipe.
• Install the RH head lamp assembly. Refer to Headlamp Replacement (Notchback) or Headlamp Replacement (Hatchback) .
• Install the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT
• Refill the engine cooling system. Refer to Cooling System Draining and Filling.

[Salto_Jorge]

Thank you for the information, but a question still remains.


With engine mount removed and the engine sitting on a transmission jack, the double row pulley will not come out due to the length of the water pumps snout and the body. Will the water pump pass between the gap ?

[EAD15]

I'm afraid I can't help with that. I had a shop replace the pump when they did my timing belt since you get most of the way to the pump when doing the belt anyway.

[Salto_Jorge]

If you have a 2009 1.6 with the water pump connected to the PS pump with a small belt in front of the engine body maybe you can help.

I was quoted over $1100 for timing and pump plus told it could be more from a chev. dealer.

How much were you charged to replace the water pump and Timing belt?


NOTE: Engine is on trans jack with 2 inch PVC pipe wedged between forward hoist hook and front body to keep engine from rotating forward. This repair is becoming a pain.

[EAD15]

My car is a 2009 1.6 (LXV engine, as is yours) as a matter if fact. I paid about $800 from a local shop. That included the parts and labor.

[Salto_Jorge]

Far less then in Colorado.

Even with the tensioner for the serpentine belt removed the double row pulley cannot clear.



Right now I am grasping at straws trying to figure out how to remove the pulley and water pump.

I did find this, may not be the exact engine.

Water Pump Pulley Replacement - LDE



http://www.autocats.ws/manual/chevro...tart_Aveo.html

I like this in their instructions: Raise engine to access the bolts.

The water pump they display has three bolts like mine in the same position.

That is all it took!

Attached the motor mount to engine
Threaded long 10x1.25 bolts into the body
Jacked up the engine on the drivers side
(This was to prevent the engine from rotating sideways)
Jammed 2 in PVC pipe between engine pull hook and body
Removed one of the long bolts.

Tools: Had to grind down the side of an E10 Torx to remove the lower forward bolt.

The water pump was in good shape.
Shaft turns easier then the new one, but it has over 90K miles on it.
Something on the passenger side has been squeaking for 20K miles, maybe it.

Putting it back together now.

Think this needs a write up.

Since things are apart, just maybe the T-Belt should be replaced.
Most things are already apart, plus drive belt tensioner has been removed.