Engine Cooling System: Removal & Installation Cadillac STS I facelift

Removal Procedure

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Disconnect the surge tank outlet hose.
5. Using the J 38185 , disengage and reposition the surge tank inlet hose clamp. See «Special Tools»(ref-338194-S08548216942009081700000) .
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 and tighten to 9 N.m (80 lb in).
4. Install the surge tank bolt and tighten to 9 N.m (80 lb in).
5. Connect the surge tank inlet hose to the surge tank.
6. Using the J 38185 , reposition the hose clamp to secure the surge tank inlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
7. Connect the surge tank outlet hose.
8. Using the J 38185 , reposition the hose clamp to secure the surge tank outlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
9. Connect the master cylinder fluid level sensor electrical connector.
10. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Using the J 38185 , disengage clamp tension and disconnect the overflow hose from the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
2. Using the J 38185 , disengage clamp tension and disconnect the outlet hose from the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Remove the fill neck bolts.
4. Using the J 38185 disengage clamp tension and disconnect the overflow hose from the reservoir. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Remove the overflow hose.

1. Install the overflow hose.
2. Using the J 38185 disengage clamp tension and connect the overflow hose onto the reservoir. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 disengage clamp tension and connect the outlet hose onto the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using the J 38185 , disengage clamp tension and connect the overflow hose onto the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Install the fill neck bolts and tighten to 9 N.m (80 lb in).
6. Inspect the level of the charge air cooling system and fill as necessary. Refer to «Charge Air Cooling System Coolant Level Inspection»(ref-338194-S31435442322009081700000) .

1. Using the J 38185 , disengage clamp tension and disconnect the overflow hose from the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
2. Using the J 38185 , disengage clamp tension and disconnect the outlet hose from the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Remove the fill neck bolts.
4. Using the J 38185 disengage clamp tension and disconnect the overflow hose from the reservoir. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Remove the overflow hose.

1. Install the overflow hose.
2. Using the J 38185 disengage clamp tension and connect the overflow hose onto the reservoir. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 disengage clamp tension and connect the outlet hose onto the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using the J 38185 , disengage clamp tension and connect the overflow hose onto the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Install the fill neck bolts and tighten to 9 N.m (80 lb in).
6. Inspect the level of the charge air cooling system and fill as necessary. Refer to «Charge Air Cooling System Coolant Level Inspection»(ref-338194-S31435442322009081700000) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Using J 38185 , disengage the hose clamp at the surge tank (1) and disconnect the surge tank inlet hose (2). See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using J 38185 , disengage the hose clamp at the radiator and disconnect the surge tank inlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using J 38185 , disengage the hose clamp at the throttle body assembly and disconnect the surge tank inlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
2. Using J 38185 , engage the hose clamp at the radiator and connect the surge tank inlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
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). See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

Scheme 2

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Using J 38185 , disengage the clamp at the surge tank and disconnect the surge tank inlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using J 38185 , disengage the clamp at the radiator and disconnect the surge tank inlet hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Using J 38185 , install the surge tank inlet hose to the surge tank. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-338203-S10562039982009081700000) .
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-338203-S10562039982009081700000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Position J 38185 to the clamp in order to remove the outlet hose (2) from the surge tank (1). See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Install the bolt to the bracket securing the surge tank outlet pipe to the engine and tighten 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). See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the thermostat housing. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator inlet hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 slide the clamp into the original position. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using the J 38185 , disengage the tension on the hose clamp and install the radiator inlet hose to the thermostat housing. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Using the J 38185 slide the clamp into the original position. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

Scheme 3

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Using the J 38185: Hose Clamp Pliers, disengage the tension on the hose clamp and remove the radiator inlet hose from the throttle body housing.
3. Using the J 38185: Hose Clamp Pliers, disengage the tension on the hose clamp (1) and remove the radiator inlet hose (2) 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: Hose Clamp Pliers, disengage the tension on the hose clamp (1) and Install the radiator inlet hose () to the radiator.
3. Using the J 38185: Hose Clamp Pliers slide the clamp into the original position.
4. Using the J 38185: Hose Clamp Pliers, disengage the tension on the hose clamp and install the radiator inlet hose to the throttle body housing.
5. Using the J 38185: Hose Clamp Pliers slide the clamp into the original position.
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Using the J 38185: Hose Clamp Pliers, disengage the tension on the hose clamp and remove the radiator inlet hose from the throttle body housing.
3. Using the J 38185: Hose Clamp Pliers, disengage the tension on the hose clamp (1) and remove the radiator inlet hose (2) 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: Hose Clamp Pliers, disengage the tension on the hose clamp (1) and Install the radiator inlet hose () to the radiator.
3. Using the J 38185: Hose Clamp Pliers slide the clamp into the original position.
4. Using the J 38185: Hose Clamp Pliers, disengage the tension on the hose clamp and install the radiator inlet hose to the throttle body housing.
5. Using the J 38185: Hose Clamp Pliers slide the clamp into the original position.
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LY7)»(ref-338194-S18903782202009081700000) or «Radiator Inlet Hose Replacement (LLT)»(ref-338194-S20034297192009081700000) or «Radiator Inlet Hose Replacement (LH2 With V92)»(ref-338194-S35264658362009081700000) or «Radiator Inlet Hose Replacement (LH2 With Out V92)»(ref-338194-S29092016972009081700000) .
3. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the thermostat housing. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Disconnect the radiator outlet hose from the engine support bracket.
5. Remove the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
6. Using the J 38185 , disengage the tension on the hose clamp and remove the radiator outlet hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 slide the clamp into the original position. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using the J 38185 , disengage the tension on the hose clamp and install the radiator outlet hose to the thermostat housing. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Using the J 38185 slide the clamp into the original position. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Install the radiator outlet hose to the engine support bracket.
7. Install the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LY7)»(ref-338194-S18903782202009081700000) or «Radiator Inlet Hose Replacement (LLT)»(ref-338194-S20034297192009081700000) or «Radiator Inlet Hose Replacement (LH2 With V92)»(ref-338194-S35264658362009081700000) or «Radiator Inlet Hose Replacement (LH2 With Out V92)»(ref-338194-S29092016972009081700000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

Scheme 4

1. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
2. Using the J 38185 , disengage clamp tension and disconnect the radiator inlet hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 , disengage clamp tension and disconnect the radiator inlet hose from the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Remove the radiator inlet hose.

1. Install the radiator inlet hose.
2. Using the J 38185 , disengage clamp tension and connect the pump inlet hose onto the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 , disengage clamp tension and connect the radiator inlet hose onto the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using the J 38185 , disengage clamp tension and connect the radiator inlet hose onto the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Fill the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .

1. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
2. Using the J 38185 , disengage clamp tension and disconnect the radiator outlet hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 , disengage clamp tension and disconnect the radiator outlet hose from the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Lower the vehicle.
5. Using the J 38185 , disengage clamp tension and disconnect the radiator outlet hose from the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Remove the radiator outlet hose.

1. Install the radiator outlet hose.
2. Using the J 38185 , disengage clamp tension and connect the radiator outlet hose onto the fill neck. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Raise the vehicle.
4. Using the J 38185 , disengage clamp tension and connect the radiator outlet hose onto the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Using the J 38185 , disengage clamp tension and connect the radiator outlet hose onto the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Fill the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .

Scheme 5

Scheme 6

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
2. Remove the left lower front bumper close out panel. Refer to «Front Air Deflector Replacement»(ref-338114-S23457007412009081700000) .
3. Install oil drain pan under the vehicle.
4. Remove the engine oil cooler hose/pipe from the external oil cooler. Refer to «Engine Oil Cooler Hose/Pipe Replacement»(ref-338194-S25112343872009081700000) .
5. Remove the external engine oil cooler quick connect fitting.
6. Remove and discard all engine oil cooler hose/pipe seals.

1. Install new engine oil cooler hose/pipe seals.
2. Install the external engine oil cooler quick connect fitting and tighten to 18 N.m (13 lb ft).
3. Install the engine oil cooler hose/pipes to the external oil cooler. Refer to «Engine Oil Cooler Hose/Pipe Replacement»(ref-338194-S25112343872009081700000) .
4. Remove the oil drain pan from under the vehicle.
5. Install the left lower front bumper close out panel. Refer to «Front Air Deflector Replacement»(ref-338114-S23457007412009081700000) .
6. Refill the engine with oil and check for leaks.

1. Install the DT-47731 onto the engine oil cooler (EOC) pipe.
2. Slide the DT-47731 toward the EOC pipe fitting.
3. Connect the DT-47731 onto the EOC pipe fitting.
4. Rotate the DT-47731 until the retainer clip (1) rises above the fitting retainer seat.
5. Pull back on the EOC pipe to disengage the pipe from the EOC pipe fitting.
6. Remove the DT-47731 from the EOC pipe.

1. Install the EOC pipe into the EOC pipe fitting. A distinct snap should be heard or felt when assembling the EOC pipe to the fitting.
2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
2. Remove the Front Air Deflector Replacement. Refer to «Front Air Deflector Replacement»(ref-338114-S23457007412009081700000) .
3. Install oil drain pan under the vehicle.
4. Remove the engine oil cooler hose/pipe from the external oil cooler. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement»(ref-338194-S05675693262009081700000) .
5. Disconnect the engine oil cooler hose/pipe clip from the fan shroud.
6. Disconnect the engine oil cooler hose/pipe clip from the engine.
7. Remove the external engine oil cooler hose/pipe from the engine. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement»(ref-338194-S05675693262009081700000) .
8. Remove the external engine oil cooler hose/pipe from the vehicle.
9. Remove and discard all engine oil cooler hose/pipe seals.

1. Install new engine oil cooler hose/pipe seals.
2. Install the external engine oil cooler hose/pipe to the vehicle.
3. Install the external engine oil cooler hose/pipe to the engine. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement»(ref-338194-S05675693262009081700000) .
4. Connect the engine oil cooler hose/pipe clip to the engine.
5. Connect the engine oil cooler hose/pipe clip to the fan shroud.
6. Install the engine oil cooler hose/pipes to the external oil cooler. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement»(ref-338194-S05675693262009081700000) .
7. Remove the oil drain pan from under the vehicle.
8. Install the Front Air Deflector Replacement. Refer to «Front Air Deflector Replacement»(ref-338114-S23457007412009081700000) .
9. Refill the engine with oil and check for leaks.

Auxiliary Engine Oil Cooler Replacement

The engine oil cooler is the top part of a combined assembly for engine oil and transmission fluid cooling. For replacement refer to Engine Oil and Transmission Fluid Cooler Replacement .

1. Remove the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
2. Loosen the fan nut from the crank adapter shaft using J 41240 . See «Special Tools»(ref-338194-S08548216942009081700000) .
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 to 100 N. See «Special Tools»(ref-338194-S08548216942009081700000) .m (74 lb ft).
3. Install the air cleaner intake duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .

1. Remove the air cleaner intake duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
2. Loosen the fan nut from the crank adapter shaft using J 41240 . See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Remove the fan shroud. Refer to «Engine Coolant Fan Shroud Replacement (LH2 With V92)»(ref-338194-S27599490992009081700000) or «Engine Coolant Fan Shroud Replacement (LH2 With Out V92, LLT)»(ref-338194-S37499515202009081700000) .
4. Continue to loosen the fan nut and disconnect the fan from the crank adapter shaft.
5. Remove the fan from the vehicle.

1. Install the fan to the vehicle.
2. Connect the fan to the crank adapter shaft.
3. Install the fan shroud. Refer to «Engine Coolant Fan Shroud Replacement (LH2 With V92)»(ref-338194-S27599490992009081700000) or «Engine Coolant Fan Shroud Replacement (LH2 With Out V92, LLT)»(ref-338194-S37499515202009081700000) .
4. Tighten the fan nut to the crank adapter shaft using J 41240 to 100 N. See «Special Tools»(ref-338194-S08548216942009081700000) .m (74 lb ft).
5. Install the air cleaner intake duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .

1. Remove the cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
2. Hold the cooling fan adapter from turning by placing a wrench on the adapter flat spots.
3. Remove the cooling fan adapter bolts.
4. Remove the cooling fan adapter from the vehicle.

1. Install the cooling fan adapter to the vehicle.
2. Hold the cooling fan adapter from turning by placing a wrench on the adapter flat spots.
3. Install the cooling fan adapter bolts and tighten to 24 N.m (18 lb ft).
4. Install the cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .
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 and tighten 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 Inlet Duct Replacement»(ref-338169-S06455195582009081700000) .

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-338130-S15906308302009081700000) .
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 and tighten 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 and tighten to 5.4 N.m (48 lb in).

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
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-338130-S15906308302009081700000) .
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 and tighten to 5.4 N.m (48 lb in).
4. Install the retaining bolts that secure the power steering lines to the cooling fan shroud and tighten 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 and tighten 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 and tighten 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 and tighten 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-338170-S38900360272009081700000) .

1. Remove the cooling fan assembly. Refer to «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
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) and tighten 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 and tighten to 7 N.m (62 lb in).
6. Install the cooling fan assembly. Refer to «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .

1. Remove the engine cooling fan. Refer to «Fan Replacement (LH2)»(ref-338194-S23483326772009081700000) .
2. Remove the fan bracket to crankshaft balancer bolts.
3. Remove the fan bracket to engine block bolts.
4. 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 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-338194-S23483326772009081700000) .

1. Disconnect the heater hoses from the heater core. Refer to «Heater Inlet Hose Replacement (LY7)»(ref-338121-S10723981692009081700000) and «Heater Outlet Hose Replacement (LY7)»(ref-338121-S25990391592009081700000) .
2. Remove the thermostat. Refer to «Engine Coolant Thermostat Replacement (LY7)»(ref-338194-S27620834792009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .

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 and tighten to 20 N.m (15 lb ft).
6. Install the thermostat. Refer to «Engine Coolant Thermostat Replacement (LY7)»(ref-338194-S27620834792009081700000) .
7. Connect the heater hoses to the heater core. Refer to «Heater Inlet Hose Replacement (LY7)»(ref-338121-S10723981692009081700000) and «Heater Inlet Hose Replacement (LY7)»(ref-338121-S10723981692009081700000) .

Scheme 7

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338172-S42418464632009081700000) .
3. Remove the radiator hose from the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
4. Remove the heater hose from the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) or «Heater Outlet Hose Replacement (LY7)»(ref-338121-S25990391592009081700000) .
5. Remove the thermostat housing bolts (4).
6. Remove the thermostat housing (3) with thermostat (1), 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 (1) to the thermostat housing (3).
3. Install the NEW seal (2) to the thermostat housing.
4. Install the thermostat housing (3) with the thermostat (1) and the seal (2) to the water housing.
5. Install the thermostat housing bolts (4) and tighten to 10 N.m (89 lb in).
6. Install the heater hose to the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) or «Heater Outlet Hose Replacement (LY7)»(ref-338121-S25990391592009081700000) .
7. Install the radiator hose to the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338172-S42418464632009081700000) .
9. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
3. Remove the radiator hose from the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
4. Remove the heater hose from the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) .
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 and tighten to 10 N.m (89 lb in).
6. Install the heater hose to the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) .
7. Install the radiator hose to the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
9. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the upper intake manifold with the lower intake manifold. Refer to «Lower Intake Manifold Replacement (LP1, LY7)»(ref-338138-S37118186722009081700000) .
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 and tighten to 10 N.m (89 lb in).
3. Install the coolant pipe (4), NEW seal, and fasteners (2 and 7). Refer to «Engine Coolant Inlet Pipe Replacement»(ref-338194-S23864519632009081700000) .
4. Install the surge tank hose to the thermostat.
5. Install the upper intake manifold with the lower intake manifold. Refer to «Lower Intake Manifold Replacement (LP1, LY7)»(ref-338138-S37118186722009081700000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the upper intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
3. Disconnect the surge tank outlet pipe from the thermostat. Refer to «Radiator Surge Tank Outlet Hose/Pipe Replacement (LH2)»(ref-338194-S41819432532009081700000) or «Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7)»(ref-338194-S12660407332009081700000) .
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 (1).
8. Remove the thermostat (2) and discard the thermostat seal (3).

1. Install the thermostat (2) with a NEW thermostat seal (3).
2. Install the thermostat bolts (1) and tighten to 10 N.m (89 lb in).
3. Install the coolant pipe (4), NEW seal, and fasteners (2 and 7). Refer to «Engine Coolant Inlet Pipe Replacement»(ref-338194-S23864519632009081700000) .
4. Connect the surge tank outlet pipe to the thermostat. Refer to «Radiator Surge Tank Outlet Hose/Pipe Replacement (LH2)»(ref-338194-S41819432532009081700000) or «Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7)»(ref-338194-S12660407332009081700000) .
5. Install the upper intake manifold. Refer to «Intake Manifold Replacement»(ref-338138-S38398417812009081700000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338172-S42418464632009081700000) .
3. Remove the radiator hose from the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
4. Remove the heater hose from the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) or «Heater Outlet Hose Replacement (LY7)»(ref-338121-S25990391592009081700000) .
5. Remove the thermostat housing bolts (4).
6. Remove the thermostat housing (3) with thermostat (1), 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 (1) to the thermostat housing (3).
3. Install the NEW seal (2) to the thermostat housing.
4. Install the thermostat housing (3) with the thermostat (1) and the seal (2) to the water housing.
5. Install the thermostat housing bolts (4) and tighten to 10 N.m (89 lb in).
6. Install the heater hose to the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) or «Heater Outlet Hose Replacement (LY7)»(ref-338121-S25990391592009081700000) .
7. Install the radiator hose to the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338172-S42418464632009081700000) .
9. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
3. Remove the radiator hose from the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
4. Remove the heater hose from the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) .
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 and tighten to 10 N.m (89 lb in).
6. Install the heater hose to the thermostat housing. Refer to «Heater Outlet Hose Replacement (LH2)»(ref-338121-S21716053812009081700000) .
7. Install the radiator hose to the thermostat housing. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-338194-S02810898572009081700000) .
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
9. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. For the LLT engine, remove the throttle body. Refer to «Throttle Body Assembly Replacement (LP1, LY7)»(ref-338169-S04911426302009081700000) .
3. Remove the radiator hose from the water outlet. Refer to «Radiator Inlet Hose Replacement (LY7)»(ref-338194-S18903782202009081700000) or «Radiator Inlet Hose Replacement (LLT)»(ref-338194-S20034297192009081700000) .
4. Remove the water outlet housing bolts.
5. Remove the water outlet.
6. Remove and discard the water outlet seals.
7. 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 and tighten to 10 N.m(89 lb in)..
4. Install the radiator hose to the water outlet. Refer to «Radiator Inlet Hose Replacement (LY7)»(ref-338194-S18903782202009081700000) or «Radiator Inlet Hose Replacement (LLT)»(ref-338194-S20034297192009081700000) .
5. For the LLT engine, install the throttle body. Refer to «Throttle Body Assembly Replacement (LP1, LY7)»(ref-338169-S04911426302009081700000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the engine cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
3. Remove the supercharger assembly. Refer to «Supercharger Replacement»(ref-338139-S11747614572009081700000) .
4. Remove the supercharger belt tensioner. Refer to «Supercharger Belt Tensioner Replacement»(ref-338139-S26432009342009081700000) .
5. Remove the inboard supercharger idler pulley. Refer to «Belt Idler Pulley Replacement - Supercharger»(ref-338139-S02572840392009081700000) .
6. Remove the two coolant hoses from the water outlet housing. Refer to «Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)»(ref-338194-S07736392202009081700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LLT)»(ref-338194-S34123853702009081700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LH2)»(ref-338194-S20511085052009081700000) .
7. Remove the radiator hose from the water outlet housing. Refer to «Radiator Inlet Hose Replacement (LY7)»(ref-338194-S18903782202009081700000) or «Radiator Inlet Hose Replacement (LLT)»(ref-338194-S20034297192009081700000) or «Radiator Inlet Hose Replacement (LH2 With V92)»(ref-338194-S35264658362009081700000) or «Radiator Inlet Hose Replacement (LH2 With Out V92)»(ref-338194-S29092016972009081700000) .
8. Reposition the lower clamp on the bypass hose.
9. Remove the bolts securing the water outlet housing to the cylinder heads.
10. Remove the water outlet housing along with the bypass hose from the engine.
11. Discard the water outlet housing gaskets.
12. Disassemble the water outlet housing if necessary. Refer to «Water Outlet Housing Disassemble»(ref-338206-S07562424032009081700000)
13. Clean and inspect the water outlet housing. Refer to «Water Outlet Housing Cleaning and Inspection»(ref-338206-S15942239692009081700000) .

1. Assemble the water outlet housing if necessary. Refer to «Water Outlet Housing Assemble»(ref-338206-S37303164052009081700000) .
2. Install NEW water outlet housing gaskets.
3. Install the water outlet housing with bypass hose to the vehicle.
4. Install the water outlet housing bolts and tighten to 25 N.m (18 lb ft).
5. Install the bypass hose clamp in the proper position.
6. Install the radiator hose to the water outlet housing. Refer to «Radiator Inlet Hose Replacement (LY7)»(ref-338194-S18903782202009081700000) or «Radiator Inlet Hose Replacement (LLT)»(ref-338194-S20034297192009081700000) or «Radiator Inlet Hose Replacement (LH2 With V92)»(ref-338194-S35264658362009081700000) or «Radiator Inlet Hose Replacement (LH2 With Out V92)»(ref-338194-S29092016972009081700000) .
7. Install the two coolant hoses to the water outlet housing. Refer to «Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)»(ref-338194-S07736392202009081700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LLT)»(ref-338194-S34123853702009081700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LH2)»(ref-338194-S20511085052009081700000) .
8. Install the supercharger idler pulley. Refer to «Belt Idler Pulley Replacement - Supercharger»(ref-338139-S02572840392009081700000) .
9. Install the supercharger belt tensioner. Refer to «Supercharger Belt Tensioner Replacement»(ref-338139-S26432009342009081700000) .
10. Install the supercharger assembly. Refer to «Supercharger Replacement»(ref-338139-S11747614572009081700000) .
11. Fill the charge air cooling system with coolant. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
12. Fill the engine cooling system with coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
13. Check the engine cooling system for leaks.
14. Check the charge air cooling system for leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-338170-S12371534402009081700000) .
3. Remove the manifold absolute pressure (MAP) sensor (3). Refer to «Manifold Absolute Pressure Sensor Replacement»(ref-338170-S33766734172009081700000) .
4. Disconnect the evaporative emission (EVAP) canister purge solenoid valve hose and electrical connector. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-338170-S41193668772009081700000) .
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-338209-S05443656082009081700000) .
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 Canister Purge Solenoid Valve Replacement»(ref-338170-S41193668772009081700000) .

1. Install the following components to the water outlet housing if previously removed: The intake manifold inlet duct and clamp and tighten to 6 N.m (53 lb in). The surge tank inlet hose fitting and tighten to 18 N.m (13 lb ft). The heater inlet hose fitting and tighten to 20 N.m (15 lb ft). The (EVAP) canister purge solenoid valve and tighten to 12 N.m (106 lb in).
2. Install NEW water outlet housing gaskets.
3. Install the water outlet housing to the vehicle.
4. Install the water outlet housing bolts and tighten to 25 N.m (18 lb ft).
5. Install the intake manifold duct clamp (1) and tighten to 6 N.m (53 lb in).
6. 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
7. Connect the evaporative emission (EVAP) canister purge solenoid valve hose and electrical connector. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(ref-338170-S41193668772009081700000) .
8. Install the manifold absolute pressure (MAP) sensor (3). Refer to «Manifold Absolute Pressure Sensor Replacement»(ref-338170-S33766734172009081700000) .
9. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(ref-338170-S12371534402009081700000) .
10. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the water outlet housing. Refer to «Water Outlet Housing Replacement (LC3)»(ref-338194-S30854652182009081700000) .
3. Compress the clamp, and remove the bypass hose from the water outlet housing.

1. Compress the clamp and install the bypass hose to the water outlet housing.
2. Install the water outlet housing. Refer to «Water Outlet Housing Replacement (LC3)»(ref-338194-S30854652182009081700000) .
3. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
4. Check the cooling system for leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
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. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338170-S38900360272009081700000) .
4. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
5. Check the cooling system for leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the generator drive belt. Refer to «Water Pump and Generator Belt Replacement»(ref-338138-S08393795412009081700000) .
3. Use the EN 46104 (1) in order to retain the water pump pulley. See «Special Tools»(ref-338194-S08548216942009081700000) .
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 and tighten 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. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Install the water pump pulley bolts and tighten to 12 N.m (106 lb in).
7. Install the generator drive belt. Refer to «Water Pump and Generator Belt Replacement»(ref-338138-S08393795412009081700000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the cooling fan. Refer to «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) or «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
3. Remove the air conditioning, power steering and water pump drive belt. Refer to «Water Pump and Air Conditioning Compressor and Power Steering Pump Belt Replacement»(ref-338139-S10934234262009081700000) .
4. Remove the air conditioning, power steering and water pump drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering, and Water Pump»(ref-338139-S02419128942009081700000) .
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-338206-S17651330222009081700000) .

1. Install the water pump and NEW seal to the engine front cover.
2. Install the water pump bolts and tighten to 10 N.m (89 lb in).
3. Install the water pump pulley to the water pump.
4. Install the water pump pulley bolts and tighten to 12 N.m (106 lb in).
5. Install the air conditioning, power steering and water pump drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering, and Water Pump»(ref-338139-S02419128942009081700000) .
6. Install the air conditioning, power steering and water pump drive belt. Refer to «Water Pump and Air Conditioning Compressor and Power Steering Pump Belt Replacement»(ref-338139-S10934234262009081700000) .
7. Install the cooling fan. Refer to «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) or «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
3. Remove the water pump drive belt. Refer to «Water Pump and Air Conditioning Compressor and Power Steering Pump Belt Replacement»(ref-338203-S07631211902009081700000) .
4. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Air Conditioning, Power Steering, and Water Pump»(ref-338203-S02247275462009081700000) .
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-338206-S17651330222009081700000) .

1. Install the water pump and NEW seal to the engine front cover.
2. Install the water pump bolts and tighten to 10 N.m (89 lb in).
3. Install the water pump pulley to the water pump.
4. Install the water pump pulley bolts and tighten 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-338203-S02247275462009081700000) .
6. Install the water pump drive belt. Refer to «Water Pump and Air Conditioning Compressor and Power Steering Pump Belt Replacement»(ref-338203-S07631211902009081700000) .
7. Install the cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) or «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Using the J 38185 slide the hose clamp down on the hose (3). See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Disconnect the hose from the auxiliary water pump.
4. Using the J 38185 slide the hose clamp back on the hose (1). See «Special Tools»(ref-338194-S08548216942009081700000) .
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 and tighten 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. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
8. Fill the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

Scheme 8

1. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338172-S42418464632009081700000) .
3. Using the J 38185 , disengage clamp tension and disconnect the supercharger inlet and outlet hoses at the supercharger. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Remove the pipe assembly to fan shroud mounting bolts.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
6. Using the J 38185 , disengage clamp tension and disconnect the pump outlet hose from the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
7. Using the J 38185 , disengage clamp tension and disconnect the radiator inlet hose from the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
8. Remove the pipe assembly mounting bolt at the condenser bracket.
9. Remove the pipe assembly.

1. Install the pipe assembly.
2. Install the pipe assembly mounting bolt to the condenser bracket and tighten to 5.4 N.m (80 lb in).
3. Using the J 38185 , disengage clamp tension and connect the radiator inlet hose onto the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Using the J 38185 , disengage clamp tension and connect the pump outlet hose onto the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Lower the vehicle.
6. Install the pipe assembly to the fan shroud mounting bolts and tighten to 5.4 N.m (80 lb in).
7. Using the J 38185 , disengage clamp tension and connect the supercharger inlet and outlet hoses onto the supercharger. See «Special Tools»(ref-338194-S08548216942009081700000) .
8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-338172-S42418464632009081700000) .
9. Fill the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .

1. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
2. Using the J 38185 , disengage clamp tension and disconnect the pump outlet hose from the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 , disengage clamp tension and disconnect the pump inlet hose from the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Disconnect and reposition the pump electrical connector.
5. Remove the pump mounting nuts.
6. Open the pump retaining clamps.
7. Remove the pump.

1. Install the pump.
2. Close the pump retaining clamps.
3. Install the pump mounting nuts and tighten to 16 N.m (12 lb ft).
4. Connect the pump electrical connector.
5. Using the J 38185 , disengage clamp tension and connect the pump inlet hose onto the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Using the J 38185 , disengage clamp tension and connect the pump outlet hose onto the pump. See «Special Tools»(ref-338194-S08548216942009081700000) .
7. Fill the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .

1. Remove the fan. Refer to «Fan Replacement (LY7)»(ref-338194-S35192878682009081700000) .
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 and tighten 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 (LY7)»(ref-338194-S35192878682009081700000) .

1. Remove the fan. Refer to «Fan Replacement (LH2)»(ref-338194-S23483326772009081700000) .
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 and tighten 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-338130-S15906308302009081700000) .
5. Install the fan. Refer to «Fan Replacement (LH2)»(ref-338194-S23483326772009081700000) .

Scheme 9

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the electric cooling fan assembly. Refer to «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
12. Use J 38185 to disconnect the surge tank inlet hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) . Reposition the hose aside.
13. Using J 38185 disengage tension on the radiator inlet hose clamp and disconnect the hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
14. Using J 38185 disengage tension on the radiator outlet hose clamp and disconnect the hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
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. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
5. Connect the surge tank inlet hose to the radiator. Use J 38185 to position the hose clamp to secure the hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Install the radiator/condenser upper support.
7. Install the radiator support brackets.
8. Install the radiator support bracket bolts and tighten 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 and tighten to 5 N.m (44 lb in).
12. Install the upper condenser mounting bolts and tighten to 5.4 N.m (48 lb in).
13. Install the lower condenser mounting bolts and tighten to 5.4 N.m (48 lb in).
14. Lower the vehicle.
15. Install the electric cooling fan assembly. Refer to «Engine Coolant Fan Replacement (LY7)»(ref-338194-S24275741032009081700000) .
16. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the electric cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
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 «Engine Coolant Fan Shroud Replacement (LH2 With V92)»(ref-338194-S27599490992009081700000) or «Engine Coolant Fan Shroud Replacement (LH2 With Out V92, LLT)»(ref-338194-S37499515202009081700000) .
9. Use J 38185 to disengage the tension on the hose clamp. See «Special Tools»(ref-338194-S08548216942009081700000) . Remove the radiator outlet hose from the radiator.
10. Use J 38185 to disengage the tension on the hose clamp. See «Special Tools»(ref-338194-S08548216942009081700000) . Remove the radiator inlet hose from the radiator.
11. Use J 38185 to disengage the tension on the hose clamp. See «Special Tools»(ref-338194-S08548216942009081700000) . 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 and tighten 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. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Connect the radiator inlet hose to the radiator. Use J 38185 to position the radiator inlet hose clamp to secure the hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
7. Connect the radiator outlet hose to the radiator. Use J 38185 to position the radiator outlet hose clamp to secure the hose. See «Special Tools»(ref-338194-S08548216942009081700000) .
8. Install the fan shroud. Refer to «Engine Coolant Fan Shroud Replacement (LH2 With V92)»(ref-338194-S27599490992009081700000) or «Engine Coolant Fan Shroud Replacement (LH2 With Out V92, LLT)»(ref-338194-S37499515202009081700000) .
9. Raise and support the vehicle.
10. Install the TOC mounting bolts and tighten 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 and tighten to 5.4 N.m (48 lb in).
13. Install the upper condenser mounting bolts and tighten to 5.4 N.m (48 lb in).
14. Install the electric cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
15. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the electric cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
3. Remove the upper condenser mounting bolts (1).
4. Remove the lower condenser mounting bolts (1).
5. Disconnect the lower retaining pins of the side air baffle from the radiator.
6. Remove the transmission oil cooler (TOC) mounting bolts (1).
7. Lower the vehicle.
8. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator outlet hose (2) from the radiator.
9. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator inlet hose (2) from the radiator.
10. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the surge tank inlet hose (2) from the radiator.
11. Remove the radiator support bracket bolts (1).
12. Remove the radiator support brackets (2).
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 (2).
4. Install the radiator support bracket bolts (1) and tighten to 9 N.m (80 lb in).
5. Connect the surge tank inlet hose (2) to the radiator. Use J 38185: Hose Clamp Pliers to position the surge tank inlet hose clamp (1) to secure the hose.
6. Connect the radiator inlet hose (2) to the radiator. Use J 38185: Hose Clamp Pliers to position the radiator inlet hose clamp (1) to secure the hose.
7. Connect the radiator outlet hose (2) to the radiator. Use J 38185: Hose Clamp Pliers to position the radiator outlet hose clamp (1) to secure the hose.
8. Raise and support the vehicle.
9. Install the TOC mounting bolts (1) and tighten 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 (1) and tighten to 5.4 N.m (48 lb in).
12. Install the upper condenser mounting bolts (1) and tighten to 5.4 N.m (48 lb in).
13. Install the electric cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
14. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .
2. Remove the electric cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
3. Remove the upper condenser mounting bolts (1).
4. Remove the lower condenser mounting bolts (1).
5. Disconnect the lower retaining pins of the side air baffle from the radiator.
6. Remove the transmission oil cooler (TOC) mounting bolts (1).
7. Lower the vehicle.
8. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator outlet hose (2) from the radiator.
9. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator inlet hose (2) from the radiator.
10. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the surge tank inlet hose (2) from the radiator.
11. Use J 38185: Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the auxiliary water pump outlet hose (2) from the radiator.
12. Remove the radiator support bracket bolts (1).
13. Remove the radiator support brackets (2).
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 (2).
4. Install the radiator support bracket bolts (1) and tighten to 9 N.m (80 lb in).
5. Connect the auxiliary water pump outlet hose to the radiator (2). Use J 38185: Hose Clamp Pliers to position the auxiliary water pump outlet hose clamp (1) to secure the hose.
6. Connect the surge tank inlet hose (2) to the radiator. Use J 38185: Hose Clamp Pliers to position the surge tank inlet hose clamp (1) to secure the hose.
7. Connect the radiator inlet hose (2) to the radiator. Use J 38185: Hose Clamp Pliers to position the radiator inlet hose clamp (1) to secure the hose.
8. Connect the radiator outlet hose (2) to the radiator. Use J 38185: Hose Clamp Pliers to position the radiator outlet hose clamp (1) to secure the hose.
9. Raise and support the vehicle.
10. Install the TOC mounting bolts (1) and tighten 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 (1) and tighten to 5.4 N.m (48 lb in).
13. Install the upper condenser mounting bolts (1) and tighten to 5.4 N.m (48 lb in).
14. Install the electric cooling fan. Refer to «Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)»(ref-338194-S16171444302009081700000) or «Engine Coolant Fan Replacement (LH2 Standard Cooling)»(ref-338194-S04299447752009081700000) .
15. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(ref-338194-S38676017542009081700000) or «Cooling System Draining and Filling (Static Fill)»(ref-338194-S21329102432009081700000) .

1. Drain the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .
2. Using the J 38185 , disengage clamp tension and disconnect the radiator inlet hose from the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
3. Using the J 38185 , disengage clamp tension and disconnect the radiator inlet hose from the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Remove the radiator inlet hose.
5. Using the J 38185 , disengage clamp tension and disconnect the radiator outlet hose from the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Remove the radiator mounting bolts.
7. Remove the radiator.

1. Install the radiator.
2. Install the radiator mounting bolts and tighten to 5.4 N.m (48 lb in).
3. Using the J 38185 , disengage clamp tension and connect the radiator outlet hose onto the radiator. See «Special Tools»(ref-338194-S08548216942009081700000) .
4. Install the radiator inlet hose.
5. Using the J 38185 , disengage clamp tension and connect the radiator inlet hose onto the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
6. Using the J 38185 , disengage clamp tension and connect the radiator inlet hose onto the pipe assembly. See «Special Tools»(ref-338194-S08548216942009081700000) .
7. Fill the charge air cooling system. Refer to «Charge Air Cooling System Draining and Filling (Static Fill)»(ref-338194-S00254263582009081700000) or «Charge Air Cooling System Draining and Filling (Vac N Fill)»(ref-338194-S05018008372009081700000) .

1. Turn the ignition OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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-338130-S15906308302009081700000) .
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

Scheme 10

Scheme 11

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a series/parallel (S/P) configuration that allows the engine control module (ECM) to operate both fans together at low or high speeds. The cooling fans receive positive voltage from the cooling fan relays which receive battery positive voltage from the underhood fuse block.

During low speed operation, the ECM supplies the ground path for the low speed fan relay through the low speed cooling fan relay control circuit. This energizes the low speed fan relay coil, closes the relay contacts, and supplies battery positive voltage from the FAN 1 fuse through the cooling fan motor supply voltage circuit to the left cooling fan. The ground path for the left cooling fan is through the S/P fan relay and the right cooling fan. The result is a series circuit with both fans running at low speed.

During high speed operation the ECM continues to supply battery positive voltage for the left cooling fan by grounding the coil of the low speed cooling fan relay. The ECM also grounds the high speed fan relay and the S/P fan relay through the high speed cooling fan relay control circuit. This energizes the S/P fan relay coil, closes the relay contacts, and provides a direct ground path for the left cooling fan. At the same time the high speed fan relay coil is energized closing the relay contacts and providing battery positive voltage from the FAN 2 fuse on the cooling fan motor supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have their own ground path. The result is a parallel circuit with both fans running at high speed.