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Discussion Starter #1
Can anyone tell me how to get the damn water pump out? The turbocharger oil supply line is right in the way. I've followed the DDM directions and have the pump off the front cover and also have all four bolts out of the water pump cover but it won"t separate into two pieces.

Thanks!
 

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Discussion Starter #3
Take the replacement pump apart so you can see how it comes apart. You need to put it back in in two pieces anyway
This is an excellent tip! Thank you Rob. Turned out there are 5 bolts on the water pump cover (as opposed to 4 stated in DDM guide) and I missed the one next to the drain plug.

However, now I can't seem to 'rotate' the water pump housing to an orientation that allows it to come out. Any additional advice?
 

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Having done this twice the best advice I can offer is it WILL come out. And go back in. Make sure the two haves are separated then just fiddle with it and it will come out. It took me about five minutes of trying different orientations to get it out the first time
 

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Discussion Starter #5 (Edited)
Having done this twice the best advice I can offer is it WILL come out. And go back in. Make sure the two haves are separated then just fiddle with it and it will come out. It took me about five minutes of trying different orientations to get it out the first time
Weird. My wife and I have spent hours trying to fiddle with it now. Any chance the turbo oil supply line routing changed? In the DDM guide it looks like it ran down instead of wrapping around the waste gate like on my car. You can see the shielding on that hard line right behind / below the loose water pump housing.

I'm sort of getting to the point of accepting my fate of having to pull the turbo charger....

Update: Pretty sure GM must have changed turbo oil supply routing at some point. Would welcome some pictures of that area on 06/07 GXP.
 

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Just so you know, GM shop manual used to give 2 choices...removal of cat and pull it out the back, or removal of the turbo.... Now they give 1, removal of turbo. But, there are people like RTE here that haven't done either....
 

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Discussion Starter #8 (Edited)
We pulled the two haves out in front of the turbo. No where near the oil line as I recall
That's kind of what I thought. That's why I suspect that the line previously routed (06/07?) under the turbocharger bearing cartridge and now routes on the compressor side of the wastegate. It prevents someone servicing the car from rotating the 2nd half (impeller half) of the pump into a position that allows it to be removed.

When I try and remove the water pump it hits one of 5 objects: The timing housing casting, the turbocharger compressor inlet, the exhaust manifold / shield, the boost control solenoid valve / hoses, or the turbocharger oil supply line. I have no idea what else to do than to start removing stuff.

I plan on calling Dave @ DDMWorks tomorrow for some extra support.

Just so you know, GM shop manual used to give 2 choices...removal of cat and pull it out the back, or removal of the turbo.... Now they give 1, removal of turbo. But, there are people like RTE here that haven't done either....
Interesting. Never quite thought about pulling it out the back although I suppose it's possible? The service instructions still appear to say that. I would think the turbo oil supply line still gets in the way, which is why I came to the conclusion of removing the turbo being the easiest. Although it seems damn near impossible to remove the turbocharger without loosening the mounts and jacking the engine up to get access to the exhaust turbine to exhaust manifold nuts.

Ironically, upon closer inspection of the service instructions, it actually shows there to be no turbocharger mounted to the exhaust manifold when pulling the water pump out. However, it doesn't instruct removal of the turbocharger which seems like an....oversight?
 

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On my '07, the DDM instructions worked fine. But, it took me way more than five minutes to get it out. I didn't have to disconnect any oil lines.
 

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I found it easier to remove the turbo while leaving the catalytic converter in place but disconnected from the exhaust. Yes, it required loosening the motor mount and jacking up the engine. Reused all gaskets, no leaks. It’s not a fun job due to lack of space.
 

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water pump relacement on 2009 GXP

This is an excellent tip! Thank you Rob. Turned out there are 5 bolts on the water pump cover (as opposed to 4 stated in DDM guide) and I missed the one next to the drain plug.

However, now I can't seem to 'rotate' the water pump housing to an orientation that allows it to come out. Any additional advice?
I fully understand your frustration re. pump replacement. I did mine back in April and it was a bear to work on - took me a total of nearly 15 hours and I'm not a novice mechanic. There are 2 lines on the turbo that I had to remove as well as the wiring connector on the front/bottom. I had to bend them slightly to finally get the clearance needed to remove the water pump, but they will go back on by re-bending back to original - no problem. The 2 lines have special washers that will need to be replaced as well. Do not reuse the old ones since they are designed as 'crush' washers. They are available from a Chevy dealer since they are also used on the turbo Cobalts. Once you remove the pump, try to remember how you oriented the parts to get them out. The back comes out easily, but the main housing is a bugger. I wish I could give you more info, but this is what I remember. Don't forget to use some silicone grease or Vaseline to hold the gaskets in place when you re-install the pump - just put enough in the grooves, don't smear any on the mating surfaces. Best of luck! Getting the air out of the system will be the next problem. I devised my own method which you can read about on my posts re. that problem. DDMs write up helps a lot, but that did not quite do it for me.

grandpop07
 

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I made the decision to not remove the turbo. In my opinion, it introduces a whole new set of potential failure modes. I think the banjo bolt seals are one time use and should be replaced, but don't quote me. :grin:

I remember leaning on the right front fender and manipulating the back half of the water pump till it came out. It came out toward the bottom. Keep at it, your ill get it.
 

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Discussion Starter #13
Thanks for the feedback everyone.

Unfortunately, it pains me to confirm that the 2009/2010 LNF engine has a different turbocharger oil supply line than the 2006-2008 cars. The line now routes around the front of the wastegate instead of under the wastegate near the oil return line. This makes it impossible to rotate the pump housing into a position that allows it to be pulled out without removing the turbo.

Hopefully this serves as a warning for 2009+ turbo Kappa cars.

Here we go with turbo removal. I'll report back good or bad at some point. Once again, thanks everyone!
 

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A lot of components on that side can be pulled out through the bottom, or through the side (by removing the big plastic wheel well / fender liner / whatever you want to call it.

Have you talked to DDM? They do a lot of these and are typically happy to provide technical assistance.


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I found that I had to unbolt and shift the power steering reservoir on mine (If I did it over again, I would remove the reservoir and hose completely) and keep rotating until I finally squeezed it through. Took me a good 20 minutes but I finally got it out.

I will say that after going through all of that, I think removing the turbo might ultimately be easier and less time consuming.
 

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Discussion Starter #17
A lot of components on that side can be pulled out through the bottom, or through the side (by removing the big plastic wheel well / fender liner / whatever you want to call it.

Have you talked to DDM? They do a lot of these and are typically happy to provide technical assistance.


Sent from my iPhone using Tapatalk
Yeah, I talked to DDM. They said you really just have to keep working it until it comes out. I'm not sure they were aware that the turbo oil supply line routing changed for 2009+ LNF engines. It really makes it impossible to remove unless you collapse the line or remove it. I don't even see how to get to the block side banjo bolt unless I remove the catalytic converter though.

I found that I had to unbolt and shift the power steering reservoir on mine (If I did it over again, I would remove the reservoir and hose completely) and keep rotating until I finally squeezed it through. Took me a good 20 minutes but I finally got it out.

I will say that after going through all of that, I think removing the turbo might ultimately be easier and less time consuming.
Funny enough, if I could get it by all the other components that aren't the power steering hose and reservoir, I wouldn't mind removing it temporarily!
The issue for me is opening up the turbo and oil lines.
Definitely not thrilled about it, but don't see what choice I have at this point.
 

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Discussion Starter #18
Update:

Got everything back together (Water Pump, Thermostat, Turbo, Cat, etc.) and now have a CEL and the dreaded 'whirring' from the front end. Going to try and fix the noise (I wouldn't really call it a whine per se) before I get a code check. I presume I can reset the balance shaft chain tension without having to remove the timing chain right? Tearing into the front end tonight, any advice appreciated...

P.S., Once this is finished, I will be posting some pictures from the water pump replacement.
 

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Update:

Got everything back together (Water Pump, Thermostat, Turbo, Cat, etc.) and now have a CEL and the dreaded 'whirring' from the front end. Going to try and fix the noise (I wouldn't really call it a whine per se) before I get a code check. I presume I can reset the balance shaft chain tension without having to remove the timing chain right? Tearing into the front end tonight, any advice appreciated...

P.S., Once this is finished, I will be posting some pictures from the water pump replacement.
Yes you can remove the tensioner without removing the chain.

Honestly though, the timing and balancing kit is cheap enough, I would do it while you are in there but that's just me. It isn't difficult if you already are tearing down the front end. See this video

Side note, removing the hood, radiator, and fan, will make your life 1000x easier and give you great access.
 

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I can verify, on his '09, the oil return line from the turbo blocked pulling the WP out. We compared and the '08 comes out and goes around the turbo...the '09 is more of a diagonal and the WP will not fit out of the opening. So something for all of you '09 owners!!
 
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