Here's a general overview of the process. This is NOT a complete guide and should not be considered a substitute for a proper repair manual specific to your Cavalier's engine (2.2L or 2.4L). You *must* consult a repair manual for detailed instructions, torque specifications, and diagrams. Incorrect torque can lead to damage.
Before You Begin:
* Safety First: Disconnect the negative battery terminal. Wear safety glasses and gloves. Have a clean workspace.
* Gather Tools and Parts: You'll need a repair manual, new water pump, new thermostat (recommended), coolant, new gasket(s), socket set (metric), wrenches, pliers, screwdrivers (Phillips and flathead), jack stands, drain pan, funnel, and possibly a radiator pressure tester.
* Cool Down: Let the engine cool completely before starting. Hot coolant will cause severe burns.
General Steps (Consult your repair manual for specifics):
1. Drain the Cooling System: Locate the drain plug on the radiator and engine block (if applicable) and carefully drain the coolant into your drain pan.
2. Remove Accessory Components: This is the most variable part depending on your engine. You'll likely need to remove:
* Serpentine Belt: This usually involves loosening the tensioner pulley.
* Fan and Fan Shroud (if applicable): May require removing the fan clutch.
* Pulley(s) on the water pump: May require special tools for removal.
* Possibly other components: Your repair manual will detail this.
3. Remove the Water Pump: This usually involves removing bolts securing the pump to the engine block. Be prepared for some coolant leakage.
4. Clean the Mounting Surface: Thoroughly clean the engine block surface where the water pump mounts to ensure a good seal with the new gasket.
5. Install the New Water Pump: Apply a thin layer of gasket sealant (if recommended by the manufacturer) to the new gasket and carefully install the new water pump, ensuring it's properly aligned. Tighten the bolts to the specified torque in the repair manual. Don't overtighten!
6. Reinstall Components: Reinstall all the components removed in step 2, reversing the removal process. Be careful to align pulleys and belts correctly.
7. Refill the Cooling System: Add coolant to the radiator and carefully fill the overflow reservoir.
8. Bleed the Air: Start the engine and let it run until it reaches operating temperature. Check for leaks. Add coolant as needed to maintain the proper level. Some systems require bleeding air from the system – your repair manual will explain how.
9. Pressure Test (Optional but Recommended): Use a radiator pressure tester to check for leaks in the cooling system.
Important Considerations:
* Repair Manual: This is absolutely essential. It will provide detailed instructions specific to your 1996 Chevy Cavalier's engine.
* Torque Specifications: Following the correct torque specifications is critical to prevent damage to the engine block or water pump.
* Coolant Type: Use the correct type and concentration of coolant as specified in your owner's manual.
* Professional Help: If you're uncomfortable with any aspect of this repair, take your car to a qualified mechanic. A botched water pump replacement can lead to serious engine damage.
This is a simplified overview. Again, do not attempt this repair without a proper repair manual for your specific vehicle. Improper repair can lead to serious damage to your engine.
