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Engine Cooling System: Removal & Installation Cadillac STS I

Cooling System (Mechanical) ~8102 words

Removal Procedure

  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Disconnect the master cylinder fluid level sensor electrical connector and reposition aside.
  3. Using the J 38185 , disengage and reposition the surge tank outlet hose clamp.
  4. Disconnect the surge tank outlet hose.
  5. Using the J 38185 , disengage and reposition the surge tank inlet hose clamp.
  6. Disconnect the surge tank inlet hose.
  7. Remove the surge tank bolt.
  8. Remove the surge tank nut.
  9. Disconnect the low coolant sensor electrical connector.
  10. Remove the surge tank.

Installation Procedure

  1. Install the surge tank.
  2. Connect the low coolant sensor electrical connector.
  3. Install the surge tank nut. Tighten: Tighten the nut to 9 N.m (80 lb in).
  4. Install the surge tank bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  5. Connect the surge tank inlet hose to the surge tank.
  6. Using the J 38185 , resposition the hose clamp to secure the surge tank inlet hose.
  7. Connect the surge tank outlet hose.
  8. Using the J 38185 , resposition the hose clamp to secure the surge tank outlet hose.
  9. Connect the master cylinder fluid level sensor electrical connector.
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Using J 38185 , disengage the hose clamp at the surge tank (1) and disconnect the surge tank inlet hose (2).
  3. Using J 38185 , disengage the hose clamp at the radiator and disconnect the surge tank inlet hose.
  4. Using J 38185 , disengage the hose clamp at the throttle body assembly and disconnect the surge tank inlet hose.
  5. Remove the surge tank inlet hose from the vehicle.
  1. Using J 38185 , engage the hose clamp at the throttle body assembly and connect the surge tank inlet hose.
  2. Using J 38185 , engage the hose clamp at the radiator and connect the surge tank inlet hose.
  3. Position the surge tank inlet hose to the retaining feature of the air cleaner assembly.
  4. Using J 38185 , engage the hose clamp at the surge tank (1) and connect the surge tank inlet hose (2).
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Using J 38185 , disengage the clamp at the surge tank and disconnect the surge tank inlet hose.
  3. Using J 38185 , disengage the clamp at the radiator and disconnect the surge tank inlet hose
  4. Remove the surge tank inlet hose from the retaining features on the fan shroud and the air cleaner assembly.
  5. Using J 38185 , disengage the clamp at the water housing assembly and disconnect the surge tank inlet hose
  6. Remove the surge tank inlet hose from the vehicle.
  1. Install the surge tank inlet hose.
  2. Using J 38185 , install the surge tank inlet hose to the water housing assembly.
  3. Insert the surge tank inlet hose into the retaining features on the fan shroud and the air cleaner housing assembly.
  4. Using J 38185 , install the surge tank inlet hose to the radiator.
  5. Using J 38185 , install the surge tank inlet hose to the surge tank.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Position J 38185 to the clamp in order to remove the outlet hose (2) from the surge tank (1).
  3. Loosen the bolt on the bracket which secures the surge tank outlet hose to the engine.
  4. Position J 38185 to the clamp in order to remove the surge tank outlet hose from the thermostat assembly.
  5. Remove the surge tank outlet hose/pipe from the engine.
  1. Position the surge tank outlet hose/pipe to the engine.
  2. Position J 38185 to the clamp in order to connect the surge tank outlet hose to the thermostat assembly.
  3. Install the bolt to the bracket securing the surge tank outlet pipe to the engine. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  4. Position J 38185 to the clamp in order to connect the outlet hose (2) to the surge tank (1).
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) in Engine Mechanical - 4.6L.
  3. Compress the clamp (1) and remove the surge tank outlet hose from the surge tank (2).
  4. Separate the hose (2) from the retaining features (1 and 3) on the front of dash.
  5. Compress the clamp (2) and remove the surge tank outlet hose from the heater hose (1).
  6. Remove the surge tank outlet hose/pipe from the engine compartment.
  1. Position the surge tank outlet hose/pipe to the engine compartment.
  2. Compress the clamp (2) and connect the surge tank outlet hose to the heater hose (1).
  3. Install the hose (2) to the retaining features (1 and 3) on the front of dash.
  4. Compress the clamp (1) and connect the surge tank outlet hose to the surge tank (2).
  5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-197575-S37763020362005101200000) in Engine Mechanical - 4.6L.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the thermostat housing.
  3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the radiator.
  4. Remove the radiator inlet hose from the vehicle.
  1. Install the inlet radiator hose into the vehicle.
  2. Using the J 38185 , disengage the tension on the hose clamp and Install the radiator inlet hose to the radiator.
  3. Using the J 38185 slide the clamp into the original position.
  4. Using the J 38185 , disengage the tension on the hose clamp and install the radiator inlet hose to the thermostat housing.
  5. Using the J 38185 slide the clamp into the original position.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the throttle body housing.
  3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the radiator.
  4. Remove the radiator inlet hose from the vehicle.
  1. Install the inlet radiator hose into the vehicle.
  2. Using the J 38185 , disengage the tension on the hose clamp and Install the radiator inlet hose to the radiator.
  3. Using the J 38185 slide the clamp into the original position.
  4. Using the J 38185 , disengage the tension on the hose clamp and install the radiator inlet hose to the throttle body housing.
  5. Using the J 38185 slide the clamp into the original position.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the thermostat housing.
  4. Disconnect the radiator outlet hose from the support bracket.
  5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  6. Remove the front air deflector retainers.
  7. Remove the front air deflector.
  8. Remove the engine control module (ECM) mounting nuts and reposition ECM aside.
  9. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the radiator.
  10. Lower the vehicle.
  11. Remove the radiator outlet hose from the vehicle.
  1. Install the radiator outlet hose to the vehicle.
  2. Raise the vehicle.
  3. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the radiator.
  4. Using the J 38185 slide the clamp into the original position.
  5. Position ECM on the mounting bracket.
  6. Install the ECM to mounting nuts. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  7. Install the front air deflector.
  8. Install the front air deflector retainers.
  9. Lower the vehicle.
  10. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the thermostat housing.
  11. Using the J 38185 slide the clamp into the original position.
  12. Install the radiator outlet hose to the support bracket.
  13. Install the air intake duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  14. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the thermostat housing.
  4. Disconnect the radiator outlet hose from the support bracket.
  5. Using the J 38185 , disengage the tension on the radiator outlet hose (1) clamp.
  6. Disconnect the radiator outlet hose (1) from the afterboil coolant pump.
  7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  8. Remove the front air deflector retainers.
  9. Remove the front air deflector.
  10. Remove the engine control module (ECM) mounting nuts and reposition ECM aside.
  11. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the radiator.
  12. Lower the vehicle.
  13. Remove the radiator outlet hose from the vehicle.
  1. Install the radiator outlet hose to the vehicle.
  2. Raise the vehicle.
  3. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the radiator.
  4. Using the J 38185 slide the clamp into the original position.
  5. Position ECM on the mounting bracket.
  6. Install the ECM to mounting nuts. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  7. Install the front air deflector.
  8. Install the front air deflector retainers.
  9. Lower the vehicle.
  10. Connect the radiator outlet hose (1) to the afterboil coolant pump.
  11. Using the J 38185 , reposition the radiator outlet hose (1) clamp to secure the radiator outlet hose to the afterboil coolant pump.
  12. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the thermostat housing.
  13. Using the J 38185 slide the clamp into the original position.
  14. Install the radiator outlet hose to the support bracket.
  15. Install the air intake duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  16. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet (LY7)»(ref-197587-S41908781802005101200000) or «Radiator Hose Replacement - Inlet (LH2)»(ref-197587-S03841261402005101200000) .
  3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the thermostat housing.
  4. Disconnect the radiator outlet hose from the engine support bracket.
  5. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-197548-S12301214282005101200000) in Engine Control - 3.6L.
  6. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the radiator.
  7. Remove the radiator outlet hose from the vehicle.
  1. Install the radiator outlet hose to the vehicle.
  2. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the radiator.
  3. Using the J 38185 slide the clamp into the original position.
  4. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the thermostat housing.
  5. Using the J 38185 slide the clamp into the original position.
  6. Install the radiator outlet hose to the engine support bracket.
  7. Install the radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet (LY7)»(ref-197587-S41908781802005101200000) or «Radiator Hose Replacement - Inlet (LH2)»(ref-197587-S03841261402005101200000) .
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Remove the air cleaner intake duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  2. Loosen the fan nut from the crank adapter shaft using J 41240 . See «Special Tools»(ref-197587-S04508623182005101200000) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  4. Disconnect the engine wiring harness from the engine frame and reposition aside.
  5. Continue to loosen the fan nut and disconnect the fan from the crank adapter shaft.
  6. Remove the fan from the vehicle.
  1. Install the fan to the vehicle.
  2. Connect the fan to the crank adapter shaft.
  3. Connect the engine wiring harness to the engine frame.
  4. Lower the vehicle.
  5. Tighten the fan nut to the crank adapter shaft using J 41240 . See «Special Tools»(ref-197587-S04508623182005101200000) . Tighten: Tighten the nut to 100 N.m (74 lb ft).
  6. Install the air cleaner intake duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  1. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-197548-S12301214282005101200000) in Engine Controls - 3.6L.
  2. Loosen the fan nut from the crank adapter shaft using J 41240 . See «Special Tools»(ref-197587-S04508623182005101200000) .
  3. Remove the fan from the vehicle.
  1. Install the fan to the vehicle.
  2. Tighten the fan nut to the crank adapter shaft using J 41240 . See «Special Tools»(ref-197587-S04508623182005101200000) . Tighten: Tighten the nut to 100 N.m (74 lb ft).
  3. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-197548-S12301214282005101200000) in Engine Controls - 3.6L.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  2. Disengage the surge tank inlet hose from the retaining features on the cooling fan shroud and reposition aside.
  3. Remove the upper retaining bolts that secure the cooling fan shroud to the radiator.
  4. Remove the LH lower retaining bolt that secures the cooling fan shroud to the radiator.
  5. Disconnect the cooling fan electrical connectors.
  6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  7. Remove the front air deflector retainers.
  8. Remove the front air deflector.
  9. Remove the RH lower retaining bolt that secures the cooling fan shroud to the radiator.
  10. Disconnect and reposition the engine wiring harness from the engine frame and reposition.
  11. Remove the retaining bolts that secure the power steering line to the cooling fan shroud.
  12. Remove the retaining bolts that secure the transmission oil cooler lines to the cooling fan shroud.
  13. Lower the vehicle.
  14. Remove the cooling fan assembly.
  1. Install the cooling fan assembly.
  2. Raise the vehicle.
  3. Install the retaining bolts that secure the transmission oil cooler lines to the cooling fan shroud. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  4. Install the retaining bolts that secure the power steering lines to the cooling fan shroud. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  5. Connect the engine wiring harness to the engine frame.
  6. Install the RH lower retaining bolt that secures the cooling fan shroud to the radiator. Tighten: Tighten the bolt to 5.4 N.m (48 lb in).
  7. Install the front air deflector.
  8. Install the front air deflector retainers.
  9. Lower the vehicle.
  10. Connect the cooling fan electrical connectors.
  11. Install the upper retaining bolts that secure the cooling fan shroud to the radiator. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  12. Install the left side lower retaining bolt that secures the cooling fan shroud to the radiator. Tighten: Tighten the bolt to 5.4 N.m (48 lb in).
  13. Engage the surge tank inlet hose to the retaining features on the cooling fan shroud.
  14. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L.
  1. Remove the upper mounting bolts that secure the auxiliary cooling fan assembly to the condenser.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  3. Remove the front air deflector retainers.
  4. Remove the front air deflector.
  5. Disconnect the electrical connectors from the auxiliary cooling fan assembly.
  6. Remove the lower mounting bolts that secure the auxiliary cooling fan assembly to the condenser.
  7. Remove the auxiliary cooling fan assembly.
  1. Install the auxiliary cooling fan assembly.
  2. Install the mounting bolts that secure the auxiliary cooling fan assembly to the condenser. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  3. Connect the electrical connectors to the auxiliary cooling fan assembly.
  4. Install the front air deflector.
  5. Install the front air deflector retainers.
  6. Lower the vehicle.
  7. Install the upper mounting bolts that secure the auxiliary cooling fan assembly to the condenser. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-197548-S12301214282005101200000) in Engine Controls - 3.6L.
  2. Disconnect the cooling fan electrical connectors.
  3. Disconnect the condenser tube from the cooling fan shroud retainer clip.
  4. Disengage the surge tank inlet hose from the retaining features on the cooling fan shroud and reposition aside.
  5. Remove the retaining bolts that secure the cooling fan shroud to the radiator.
  6. Remove the cooling fan assembly.
  1. Install the cooling fan assembly.
  2. Install the retaining bolts that secure the cooling fan shroud to the radiator. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  3. Engage the surge tank inlet hose to the retaining features on the cooling fan shroud.
  4. Connect the condenser tube to the cooling fan shroud retainer clip.
  5. Connect the cooling fan electrical connectors.
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-197548-S12301214282005101200000) in Engine Controls - 3.6L.
  1. Remove the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  2. Remove the fan blade retaining nut (1) from the motor.
  3. Remove the fan blade from the motor shaft.
  4. Remove the motor retaining screws (1).
  5. Remove the motor from the shroud.
  1. Install the motor to the shroud.
  2. Install the cooling fan motor retaining screws (1). Tighten: Tighten the screws to 5 N.m (44 lb in).
  3. Install the fan blade to the motor shaft.
  4. Rotate the fan until the fan drops onto the shaft.
  5. Install the fan blade retaining nut (1) to the motor. Tighten: Tighten the nut to 7 N.m (62 lb in).
  6. Install the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  1. Remove the engine cooling fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  2. With the aid of an assistant, tap the engine ignition until the fan bracket to crankshaft balancer bolts are accessible.
  3. Remove the fan bracket to crankshaft balancer bolts.
  4. Remove the fan bracket to engine block bolts.
  5. Remove the fan bracket from the vehicle.
  1. Install the fan bracket to the engine.
  2. Install but DO NOT tighten the fan bracket to engine block bolts.
  3. If necessary, with the aid of an assistant, tap the engine ignition until the fan bracket to crankshaft balancer bolt holes are accessible.
  4. Install the fan bracket to crankshaft balancer bolts. Tighten: Tighten the fan bracket to crankshaft balancer bolts to 24 N.m (18 lb ft). Tighten the fan bracket to engine block bolts to 24 N.m (18 lb ft).
  5. Install the engine cooling fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  1. Remove the engine cooling fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  2. Remove the fan bracket to engine block bolts.
  3. Remove the fan bracket from the vehicle.
  4. Remove the adapter studs from the crankshaft balancer, if necessary.
  1. If previously removed, install the adapter studs to the crankshaft balancer. Tighten: Tighten the engine cooling fan adapter studs to 22 N.m (16 lb ft).
  2. Align the adapter assembly to the studs on the crankshaft.
  3. Install the fan adapter to the engine.
  4. Install the fan adapter to engine block bolts. Tighten: Tighten the fan adapter to engine block bolts to 50 N.m (37 lb ft).
  5. Install the engine cooling fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls-4.6L (LH2).
  3. Remove the radiator hose from the thermostat housing. Refer to «Radiator Hose Replacement - Outlet (LH2 Standard Cooling)»(ref-197587-S41474697472005101200000) or «Radiator Hose Replacement - Outlet (LH2 Heavy Duty Cooling)»(ref-197587-S23688354742005101200000) or «Radiator Hose Replacement - Outlet (LY7)»(ref-197587-S07268288452005101200000) .
  4. Remove the heater hose from the thermostat housing. Refer to «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) in Heating, Ventilation and Air Conditioning.
  5. Remove the thermostat housing bolts.
  6. Remove the thermostat housing (1) with thermostat (3), from the water housing.
  7. Remove and discard the seal ring (2).
  8. Remove the thermostat from the thermostat housing.
  1. Clean the thermostat housing and water housing sealing surfaces.
  2. Install the thermostat to the thermostat housing.
  3. Install the NEW seal (2) to the thermostat housing.
  4. Install the thermostat housing (1) with the thermostat (3) and the seal (2) to the water housing.
  5. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).
  6. Install the heater hose to the thermostat housing. Refer to «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) in Heating, Ventilation and Air Conditioning.
  7. Install the radiator hose to the thermostat housing. Refer to «Radiator Hose Replacement - Outlet (LH2 Standard Cooling)»(ref-197587-S41474697472005101200000) or «Radiator Hose Replacement - Outlet (LH2 Heavy Duty Cooling)»(ref-197587-S23688354742005101200000) or «Radiator Hose Replacement - Outlet (LY7)»(ref-197587-S07268288452005101200000) .
  8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls-4.6L (LH2).
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Disconnect the heater hoses from the heater core. Refer to «Heater Hose Replacement - Inlet (LY7)»(ref-197627-S34274558512005101200000) or «Heater Hose Replacement - Inlet (LH2)»(ref-197627-S29921844502005101200000) and «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) in Heating, Ventilation and Air Conditioning.
  2. Remove the thermostat. Refer to «Thermostat Replacement (LH2)»(ref-197587-S35017316652005101200000) or «Thermostat Replacement (LY7)»(ref-197587-S12685784742005101200000) .
  3. Remove the thermostat housing bolts.
  4. Remove the thermostat housing with the heater pipes, hoses and bolts.
  5. Carefully clean the sealing surfaces with a plastic gasket scraper such as J 28410 or equivalent.
  1. Assemble the heater pipes and hoses to the thermostat housing.
  2. Install a new gasket to the thermostat housing.
  3. Install the thermostat housing bolts to the thermostat housing. Partially install the thermostat housing bolts in order to retain the gasket.
  4. Install the thermostat housing with the heater pipes, heater hoses, gasket and bolts.
  5. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 20 N.m (15 lb ft).
  6. Install the thermostat. Refer to «Thermostat Replacement (LH2)»(ref-197587-S35017316652005101200000) or «Thermostat Replacement (LY7)»(ref-197587-S12685784742005101200000) .
  7. Connect the heater hoses to the heater core. Refer to «Heater Hose Replacement - Inlet (LY7)»(ref-197627-S34274558512005101200000) or «Heater Hose Replacement - Inlet (LH2)»(ref-197627-S29921844502005101200000) and «Heater Hose Replacement - Inlet (LY7)»(ref-197627-S34274558512005101200000) or «Heater Hose Replacement - Inlet (LH2)»(ref-197627-S29921844502005101200000) in Heating, Ventilation and Air Conditioning.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L (LH2).
  3. Remove the radiator hose from the thermostat housing. Refer to «Radiator Hose Replacement - Outlet (LH2 Standard Cooling)»(ref-197587-S41474697472005101200000) or «Radiator Hose Replacement - Outlet (LH2 Heavy Duty Cooling)»(ref-197587-S23688354742005101200000) or «Radiator Hose Replacement - Outlet (LY7)»(ref-197587-S07268288452005101200000) .
  4. Remove the heater hose from the thermostat housing. Refer to «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) in Heating, Ventilation and Air Conditioning.
  5. Remove the thermostat housing bolts.
  6. Remove the thermostat housing (1) with thermostat (3), from the water housing.
  7. Remove and discard the seal ring (2).
  8. Remove the thermostat from the thermostat housing.
  1. Clean the thermostat housing and water housing sealing surfaces.
  2. Install the new thermostat to the thermostat housing.
  3. Install the NEW seal (2) to the thermostat housing.
  4. Install the thermostat housing (1) with the thermostat (3) and the seal (2) to the water housing.
  5. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).
  6. Install the heater hose to the thermostat housing. Refer to «Heater Hose Replacement - Outlet (LY7)»(ref-197627-S35047500202005101200000) or «Heater Hose Replacement - Outlet (LH2)»(ref-197627-S35921984332005101200000) in Heating, Ventilation and Air Conditioning.
  7. Install the radiator hose to the thermostat housing. Refer to «Radiator Hose Replacement - Outlet (LH2 Standard Cooling)»(ref-197587-S41474697472005101200000) or «Radiator Hose Replacement - Outlet (LH2 Heavy Duty Cooling)»(ref-197587-S23688354742005101200000) or «Radiator Hose Replacement - Outlet (LY7)»(ref-197587-S07268288452005101200000) .
  8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L (LH2).
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the upper intake manifold with the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-197574-S30232017352005101200000) in Engine Mechanical - 3.6L (LY7).
  3. Disconnect the surge tank hose from the thermostat.
  4. Remove the coolant pipe/thermostat housing bolt (2).
  5. Remove the coolant pipe upper bolt (7).
  6. Remove the coolant inlet pipe (4) from the thermostat.
  7. Remove the thermostat bolts.
  8. Remove the thermostat and discard the thermostat seal.
  1. Install the thermostat with a NEW thermostat seal.
  2. Install the thermostat bolts. Tighten: Tighten the thermostat bolts to 10 N.m (89 lb in).
  3. Install the coolant pipe (4), NEW seal, and fasteners (2 and 7). Refer to «Coolant Pipe Replacement - Inlet (LY7)»(ref-197587-S04515295832005101200000) .
  4. Install the surge tank hose to the thermostat.
  5. Install the upper intake manifold with the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(ref-197574-S30232017352005101200000) in Engine Mechanical - 3.6L (LY7).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-197553-S10307199032005101200000) in Engine Controls - 4.6L (LH2).
  3. Remove the manifold absolute pressure (MAP) sensor (3). Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-197553-S26545333932005101200000) in Engine Controls - 4.6L (LH2).
  4. Disconnect the evaporative emission (EVAP) canister purge solenoid valve hose and electrical connector. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-197553-S42259728992005101200000) in Engine Controls - 4.6L (LH2).
  5. Compress the clamps and remove the following hoses from the thermostat and the water housing: The heater inlet hose (1) The radiator inlet hose (2) The heater outlet hose (3) The bypass hose (4) The surge tank inlet hose
  6. Loosen the intake manifold duct clamp (1).
  7. Remove the bolts (1, 2) securing the water outlet housing to the cylinder heads.
  8. Remove the water outlet housing from the vehicle.
  9. Discard the water outlet housing gaskets.
  10. Clean and inspect the water outlet housing. Refer to «Water Outlet Housing Cleaning and Inspection»(ref-197630-S30306483752005101200000) in Engine Mechanical - 4.6L.
  11. Remove the following components from the water outlet housing if replacement is necessary: The intake manifold inlet duct and clamp The surge tank inlet hose fitting The heater inlet hose fitting The evaporative emission (EVAP) canister purge solenoid valve - Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-197553-S42259728992005101200000) in Engine Controls - 4.6L.
  1. Install the following components to the water outlet housing if previously removed: The intake manifold inlet duct and clamp Tighten: Tighten the manifold inlet duct clamp to 6 N.m (53 lb in). The surge tank inlet hose fitting Tighten: Tighten the surge tank inlet hose fitting to 18 N.m (13 lb ft). The heater inlet hose fitting Tighten: Tighten the heater inlet hose fitting to 20 N.m (15 lb ft). The (EVAP) canister purge solenoid valve Tighten: Tighten the purge solenoid valve bolt to 12 N.m (106 lb in).
  2. Install NEW water outlet housing gaskets.
  3. Bolt (2) is approximately 10 mm longer than the other three bolts (1).
  4. Install the water outlet housing to the vehicle.
  5. Install the water outlet housing bolts. Tighten: Tighten the water outlet housing bolts to 25 N.m (18 lb ft).
  6. Tighten the intake manifold duct clamp (1). Tighten: Tighten the intake manifold inlet duct clamp to 6 N.m (53 lb in).
  7. Compress the clamps and install the following hoses to the thermostat and the water housing: The heater inlet hose (1) The radiator inlet hose (2) The heater outlet hose (3) The bypass hose (4) The surge tank inlet hose
  8. Connect the evaporative emission (EVAP) canister purge solenoid valve hose and electrical connector. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(ref-197553-S42259728992005101200000) in Engine Controls - 4.6L (LH2).
  9. Install the manifold absolute pressure (MAP) sensor (3). Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(ref-197553-S26545333932005101200000) in Engine Controls - 4.6L (LH2).
  10. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-197553-S10307199032005101200000) in Engine Controls - 4.6L (LH2).
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the radiator hose from the water outlet. Refer to «Radiator Hose Replacement - Inlet (LY7)»(ref-197587-S41908781802005101200000) or «Radiator Hose Replacement - Inlet (LH2)»(ref-197587-S03841261402005101200000) .
  3. Remove the water outlet housing bolts.
  4. Remove the water outlet.
  5. Remove and discard the water outlet seals.
  6. Clean the water outlet housing sealing surfaces.
  1. Install NEW water outlet housing seals.
  2. Install the water outlet.
  3. Install the water outlet bolts. Tighten: Tighten the water outlet housing bolts to 10 N.m (89 lb in).
  4. Install the radiator hose to the water outlet. Refer to «Radiator Hose Replacement - Inlet (LY7)»(ref-197587-S41908781802005101200000) or «Radiator Hose Replacement - Inlet (LH2)»(ref-197587-S03841261402005101200000) .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  2. Remove the coolant pipe to generator bracket bolt.
  3. Lower the vehicle.
  4. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  5. Disconnect the radiator outlet hose from the coolant pipe. Refer to «Radiator Hose Replacement - Outlet (LH2 Standard Cooling)»(ref-197587-S41474697472005101200000) or «Radiator Hose Replacement - Outlet (LH2 Heavy Duty Cooling)»(ref-197587-S23688354742005101200000) or «Radiator Hose Replacement - Outlet (LY7)»(ref-197587-S07268288452005101200000) .
  6. Remove the wiring harnesses from the coolant inlet pipe.
  7. Remove the coolant pipe to thermostat bolt.
  8. Remove the coolant pipe to cylinder head bolt.
  9. Remove the coolant pipe.
  1. Install the coolant pipe.
  2. Loose assemble all the coolant pipe bolts.
  3. Install the coolant pipe to thermostat bolt. Tighten: Tighten the coolant pipe to thermostat bolt to 23 N.m (17 lb ft).
  4. Install the coolant pipe to cylinder head bolt. Tighten: Tighten the coolant pipe to cylinder head bolt to 50 N.m (37 lb ft).
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  6. Install the coolant pipe to generator bracket bolt. Tighten: Tighten the coolant pipe to generator bracket bolt to 23 N.m (17 lb ft).
  7. Connect the radiator outlet hose to the coolant pipe. Refer to «Radiator Hose Replacement - Outlet (LH2 Standard Cooling)»(ref-197587-S41474697472005101200000) or «Radiator Hose Replacement - Outlet (LH2 Heavy Duty Cooling)»(ref-197587-S23688354742005101200000) or «Radiator Hose Replacement - Outlet (LY7)»(ref-197587-S07268288452005101200000) .
  8. Install the wiring harnesses to the coolant inlet pipe.
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L (LH2).
  3. Compress the clamp, and remove the heater outlet hose (3) from the thermostat housing in order to gain access to the bypass hose.
  4. Compress the clamps (1, 3) and remove the bypass hose (2) from the water outlet housing and the front cover.
  1. Compress the clamps (1, 3) and install the bypass hose (2) to the water outlet housing and the front cover.
  2. Compress the clamp, and install the heater outlet hose (3) to the thermostat housing.
  3. Compress the clamp, and remove the heater outlet hose (3) from the thermostat housing in order to gain access to the bypass hose.
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-197553-S04945234442005101200000) in Engine Controls - 4.6L (LH2).
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the cooling fan. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) or «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  3. Remove the water pump drive belt. Refer to «Drive Belt Replacement - Air Conditioning, Power Steering and Water Pump»(ref-197575-S22002905792005101200000) in Engine Mechanical - 4.6L (LH2).
  4. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering and Water Pump»(ref-197575-S11881171232005101200000) in Engine Mechanical - 4.6L (LH2).
  5. Remove the water pump pulley bolts.
  6. Remove the water pump pulley from the water pump.
  7. Remove the water pump bolts.
  8. Remove the water pump and seal. Do not reuse the seal.
  9. Clean the water pump mating surfaces.
  10. Clean and inspect the water pump. Refer to «Water Pump Cleaning and Inspection»(ref-197630-S31892827482005101200000) in Engine Mechanical - 4.6L (LH2).
  1. Install the water pump and NEW seal to the engine front cover.
  2. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
  3. Install the water pump pulley to the water pump.
  4. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 12 N.m (106 lb in).
  5. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering and Water Pump»(ref-197575-S11881171232005101200000) in Engine Mechanical - 4.6L (LH2).
  6. Install the water pump drive belt. Refer to «Drive Belt Replacement - Air Conditioning, Power Steering and Water Pump»(ref-197575-S22002905792005101200000) in Engine Mechanical - 4.6L (LH2).
  7. Install the cooling fan. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) or «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the generator drive belt. Refer to «Drive Belt Replacement - Generator and Water Pump»(ref-197574-S15822453292005101200000) in Engine Mechanical - 3.6L (LY7).
  3. Use the EN 46104 (1) in order to retain the water pump pulley.
  4. Remove the water pump pulley bolts.
  5. Remove the water pump pulley.
  6. Remove the water pump bolts.
  7. Remove the water pump.
  8. Remove and DISCARD the water pump seal.
  9. Carefully clean the water pump sealing surfaces.
  1. Install a NEW water pump seal.
  2. Install the water pump.
  3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
  4. Install the water pump pulley and the water pump pulley bolts.
  5. Use the EN 46104 (1) in order to retain the water pump pulley.
  6. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 12 N.m (106 lb in).
  7. Install the generator drive belt. Refer to «Drive Belt Replacement - Generator and Water Pump»(ref-197574-S15822453292005101200000) in Engine Mechanical - 3.6L (LY7).
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Using the J 38185 slide the hose clamp down on the hose (3).
  3. Disconnect the hose from the auxiliary water pump.
  4. Using the J 38185 slide the hose clamp back on the hose (1).
  5. Disconnect the hose from the auxiliary water pump.
  6. Disconnect the auxiliary water pump electrical connector.
  7. Remove the auxiliary water pump nuts.
  8. Remove the auxiliary water pump.
  1. Install the auxiliary water pump.
  2. Install the auxiliary water pump nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  3. Connect the auxiliary water pump electrical connector.
  4. Connect the hose (3) to the auxiliary water pump.
  5. Using the J 38185 slide the hose clamp back into the original position on the hose.
  6. Connect the hose (1) to the auxiliary water pump.
  7. Using the J 38185 slide the hose clamp back to the original position on the hose.
  8. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Using the J 38185 slide the hose clamp down on the hose (3).
  3. Disconnect the hose from the afterboil coolant pump.
  4. Using the J 38185 slide the hose clamp back on the hose (1).
  5. Disconnect the hose from the afterboil coolant pump.
  6. Disconnect the afterboil coolant pump electrical connector from the afterboil coolant pump.
  7. Remove the afterboil coolant pump nuts.
  8. Remove the afterboil coolant pump.
  1. Install the afterboil coolant pump.
  2. Install the afterboil coolant pump nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  3. Connect the afterboil coolant pump electrical connector to the afterboil coolant pump.
  4. Connect the hose (3) to the afterboil coolant pump.
  5. Using the J 38185 slide the hose clamp back into the original position on the hose.
  6. Connect the hose (1) to the afterboil coolant pump.
  7. Using the J 38185 slide the hose clamp back to the original position on the hose.
  8. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Remove the fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  2. Lower the vehicle.
  3. Disconnect the condenser tube from the fan shroud retainer clip.
  4. Remove the cooling fan shroud retaining bolts.
  5. Remove the cooling fan shroud.
  1. Install the cooling fan shroud.
  2. Install the cooling fan shroud retaining bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  3. Connect the condenser tube to the fan shroud retainer clip.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  5. Install the fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  1. Remove the fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  2. Disconnect the condenser tube from the fan shroud retainer clip.
  3. Remove the cooling fan shroud retaining bolts.
  4. Remove the cooling fan shroud.
  1. Install the cooling fan shroud.
  2. Install the cooling fan shroud retaining bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  3. Connect the condenser tube to the fan shroud retainer clip.
  4. Install the fan. Refer to «Fan Replacement (LH2)»(ref-197587-S03651773992005101200000) or «Fan Replacement (LY7)»(ref-197587-S17673645992005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the electric cooling fan. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  3. Remove the upper condenser mounting bolts.
  4. Remove the lower condenser mounting bolts.
  5. Disconnect the lower retaining pins of the side air baffle from the radiator.
  6. Remove the transmission oil cooler (TOC) mounting bolts.
  7. Lower the vehicle.
  8. Use J 38185 to disengage the tension on the hose clamp. Remove the radiator outlet hose from the radiator.
  9. Use J 38185 to disengage the tension on the hose clamp. Remove the radiator inlet hose from the radiator.
  10. Use J 38185 to disengage the tension on the hose clamp. Remove the surge tank inlet hose from the radiator.
  11. Remove the radiator support bracket bolts.
  12. Remove the radiator support brackets.
  13. Disconnect the upper air baffle retaining pins from the radiator.
  14. Remove the radiator.
  1. Install the radiator.
  2. Connect the upper air baffle retaining pins to the radiator.
  3. Install the radiator support brackets.
  4. Install the radiator support bracket bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  5. Connect the surge tank inlet hose to the radiator. Use J 38185 to position the surge tank inlet hose clamp to secure the hose.
  6. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.
  7. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose.
  8. Raise and support the vehicle.
  9. Install the TOC mounting bolts. Tighten: Tighten the bolts to 5 N.m (44 lb in).
  10. Connect the lower retaining pins of the side air baffle to the radiator.
  11. Install the lower condenser mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  12. Install the upper condenser mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  13. Install the electric cooling fan. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  14. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the electric cooling fan. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  3. Remove the upper condenser mounting bolts.
  4. Remove the lower condenser mounting bolts.
  5. Disconnect the lower retaining pins of the side air baffle from the radiator.
  6. Remove the transmission oil cooler (TOC) mounting bolts.
  7. Lower the vehicle.
  8. Remove the fan shroud. Refer to «Fan Shroud Replacement (LH2)»(ref-197587-S39769402102005101200000) or «Fan Shroud Replacement (LY7)»(ref-197587-S07746786572005101200000) .
  9. Use J 38185 to disengage the tension on the hose clamp. Remove the radiator outlet hose from the radiator.
  10. Use J 38185 to disengage the tension on the hose clamp. Remove the radiator inlet hose from the radiator.
  11. Use J 38185 to disengage the tension on the hose clamp. Remove the surge tank inlet hose from the radiator.
  12. Remove the radiator support bracket bolts.
  13. Remove the radiator support brackets.
  14. Disconnect the upper air baffle retaining pins from the radiator.
  15. Remove the radiator.
  1. Install the radiator.
  2. Connect the upper air baffle retaining pins to the radiator.
  3. Install the radiator support brackets.
  4. Install the radiator support bracket bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  5. Connect the surge tank inlet hose to the radiator. Use J 38185 to position the surge tank inlet hose clamp to secure the hose.
  6. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.
  7. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose.
  8. Install the fan shroud. Refer to «Fan Shroud Replacement (LH2)»(ref-197587-S39769402102005101200000) or «Fan Shroud Replacement (LY7)»(ref-197587-S07746786572005101200000) .
  9. Raise and support the vehicle.
  10. Install the TOC mounting bolts. Tighten: Tighten the bolts to 5 N.m (44 lb in).
  11. Connect the lower retaining pins of the side air baffle to the radiator.
  12. Install the lower condenser mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  13. Install the upper condenser mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  14. Install the electric cooling fan. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  15. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .

Radiator Replacement (LY7 Standard Cooling)

Tools Required

  1. J 38185 Hose Clamp Pliers
  2. J 38778 Door Trim Pad Clip Remover
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  2. Remove the electric cooling fan assembly. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) .
  4. Remove the lower condenser mounting bolts.
  5. Remove the upper condenser mounting bolts.
  6. Remove the transmission oil cooler mounting bolts.
  7. Disconnect the lower retainer pins of the side air baffle from the radiator.
  8. Lower the vehicle.
  9. Remove the radiator support bracket bolts.
  10. Remove the radiator support brackets.
  11. Use J 38778 to remove the radiator/condenser upper support.
  12. Use J 38185 to disconnect the surge tank inlet hose from the radiator. Reposition the hose aside.
  13. Using J 38185 disengage tension on the radiator inlet hose clamp and disconnect the hose from the radiator.
  14. Using J 38185 disengage tension on the radiator outlet hose clamp and disconnect the hose from the radiator.
  15. Disconnect the upper retainer pins on the side air baffle from the radiator.
  16. Remove the radiator.
  1. Install the radiator.
  2. Connect the upper retainer pins of the side air baffle to the radiator.
  3. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose.
  4. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose.
  5. Connect the surge tank inlet hose to the radiator. Use J 38185 to position the hose clamp to secure the hose.
  6. Install the radiator/condenser upper support.
  7. Install the radiator support brackets.
  8. Install the radiator support bracket bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  9. Raise and support the vehicle.
  10. Connect the lower retainer pins of the side air baffle to the radiator.
  11. Install the transmission oil cooler mounting bolts. Tighten: Tighten the bolts to 5 N.m (44 lb in).
  12. Install the upper condenser mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  13. Install the lower condenser mounting bolts. Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
  14. Lower the vehicle.
  15. Install the electric cooling fan assembly. Refer to «Cooling Fan Replacement - Electric (LH2 Standard Cooling)»(ref-197587-S13199517382005101200000) or «Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling)»(ref-197587-S07214236982005101200000) or «Cooling Fan Replacement - Electric (LY7)»(ref-197587-S21582886282005101200000) .
  16. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197587-S04962200472005101200000) .
  1. Remove the radiator support bolts.
  2. Remove the radiator support brackets.
  1. Install the radiator support brackets.
  2. Install the radiator support bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  2. Disconnect the coolant heater power supply cord from the coolant heater.
  3. Complete the following in order to remove the coolant heater from the engine block: Pry outward on the retaining clip. Pull the coolant heater from the engine block.
  1. Install the coolant heater into the engine block until the retaining clip is fully engaged.
  2. Connect the coolant heater power cord to the coolant heater.
  3. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  2. Disconnect the coolant heater power supply cord from the coolant heater.
  3. Complete the following in order to remove the coolant heater from the engine block: Pry outward on the retaining clip. Pull the coolant heater from the engine block.
  1. Install the coolant heater into the engine block until the retaining clip is fully engaged.
  2. Connect the coolant heater power cord to the coolant heater.
  3. Lower the vehicle.
  1. Turn the ignition OFF.
  2. Raise and support the vehicle.
  3. Disconnect the coolant heater cord from the coolant heater.
  4. Remove the coolant heater.
  1. Install the coolant heater.
  2. Connect the coolant heater cord to the coolant heater.
  3. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  2. Disconnect the coolant heater power supply cord from the coolant heater.
  3. Lower the vehicle.
  4. Disconnect the coolant heater cord clips from the following: The engine wiring harness conduit The engine oil level indicator tube
  5. Remove the coolant heater cord from the vehicle.
  1. Position the coolant heater power supply cord to the engine.
  2. Route the coolant heater cord along the engine wiring harness conduit.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  4. Connect the coolant heater cord to the coolant heater.
  5. Secure the coolant heater cord clip to the coolant heater cord.
  6. Lower the vehicle.
  7. Secure the coolant heater cord clips to the following: The engine wiring harness conduit The engine oil level indicator tube
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  2. Disconnect the coolant heater power supply cord from the coolant heater (1).
  3. Disconnect the coolant heater cord clip (2) from the coolant heater cord.
  4. Lower the vehicle.
  5. Disconnect the coolant heater cord clips (3, 4) from the following: The engine wiring harness conduit The engine oil level indicator tube
  6. Remove the coolant heater cord from the vehicle.
  1. Position the coolant heater power supply cord to the engine.
  2. Route the coolant heater cord along the engine wiring harness conduit.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197567-S01952905382005101200000) in General Information.
  4. Connect the coolant heater cord to the coolant heater (1).
  5. Secure the coolant heater cord clip (2) to the coolant heater cord.
  6. Lower the vehicle.
  7. Secure the coolant heater cord clips (3, 4) to the following: The engine wiring harness conduit The engine oil level indicator tube

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