2200 external coolant leak (fixed) - Maintenance and Repair Forum

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2200 external coolant leak (fixed)
Saturday, February 24, 2007 10:07 PM
Just putting this info up in case someone else has this problem.

Symptoms: Loss of coolant, possible puddle under car, steam coming from engine bay, hoses seem to be in tact.

Cause: Bad water pump. What I couldn't find by searching here is that the pump actually has two weep holes, so even if the one on top looks perfectly dry, coolant is probably still leaking out of the lower one. The replacement pump I bought has two weep holes as well.

Fix: Install new water pump and gasket.
1. Loosen as many water pump pulley bolts as you can while the belt is still on, it's easer this way.
2. Remove alternator (3 bolts)
3. Remove alternator bracket (2 bolts, 2 nuts)
4. Remove water pump pulley (3 bolts)
5. Remove water pump (4 bolts)
6. Completely remove the old gasket and clean the mating surface (extremely tedious and almost impossible without a gasket remover spray).
7. Use RTV sealant on the new seal and pump and reinstall pump.
8. Reinstall pump pulley
9. Reinstall alternator bracket
10.Reinstall alternator
11. Fill coolant reservoir and install cap
12. Run engine until the fan has been on for ten minutes or so
13. Let the engine cool to ambient temp (never remove reservoir cap on a hot engine)
14. Repeat steps 11-13 until the coolant level in the reservoir does not decrease anymore.

Cost: ~$26 USD

2002 Cavalier 2200 5spd


Re: 2200 external coolant leak (fixed)
Sunday, February 25, 2007 4:52 AM
Just some additional advice, rtv is not needed on a paper gasket, if you are going to put any thing on it I would recommend permatex aviation gasket maker but not rtv.

When filling the system back up do not put the cap back on the reservoir Before filling open the bleeder on the drivers side of the head. Fill system until no air is coming out of the bleeder(coolant will flow out will no bubbles). Tight bleeder and run car with cap off, turn you heater on if the temp gauge show the engine is warm but you have no hot air their is still air in the system. Shut the car off an open the bleed until all air is removed. You may have to repeat this several times until the all the air is purged. you will know all air is out when you have nice heat, top off the coolant and cap it.
Re: 2200 external coolant leak (fixed)
Sunday, February 25, 2007 11:42 AM
FYI - I've done 3 now, also for leaks though the weep hole. I did not need to remove the alternator. Used no RTV or gasket maker, just the gasket supplied with the new water pump. Time for job, approx 1 hour.
Re: 2200 external coolant leak (fixed)
Sunday, February 25, 2007 8:07 PM
I'm not sure how you removed all of the old gasket with the alternator and bracket still in place. Even with these parts out, it took me an hour of spraying and scraping to get all the old material off.

2002 Cavalier 2200 5spd

Re: 2200 external coolant leak (fixed)
Monday, February 26, 2007 3:17 PM
The gaskets I used and removed were a 1 piece leather type gasket. They all came almost clean off in one piece when pulled slow,y and carefully. A few strokes with a gasket scraper - a careful run of the finger to locates any stuck parts - a few more scrapes with the scraper and done. Any really stuck parts - a quick spray with gasket remover/disolver - sit a minutes and off she comes. Now if some one used RTV or gasket maker, that's a different story. Now you are in for some time consuming cleaning.
Re: 2200 external coolant leak (fixed)
Monday, February 26, 2007 5:28 PM
I don't remove the alternator, but I use a die grinder with a scotch disc on it to clean it up, and aviation actually makes it come off easier. I've done more then I care to count.
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