Engine Cooling System: Removal & Installation Chevrolet Aveo I facelift

Removal Procedure

1. Disconnect the negative battery cable.
2. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
3. Remove the rear timing belt cover (2). Refer to Timing Belt Cover Replacement.
4. Remove the coolant pump nuts (2).
5. Remove the bolts (1).
6. Remove the coolant pump (3,4).
7. Remove the gasket.

Installation Procedure

1. Install the coolant pump with new gasket.
2. Install the coolant pump mounting bolts (1) and nuts. Tighten: Tighten the bolts and the nuts to 10 N.m (89 lb in).
3. Install the rear timing belt cover (1). Refer to Timing Belt Cover Replacement.
4. Fill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
5. Connect the negative battery cable.

1. Drain the engine cooling system to a level below the thermostat housing. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
2. Remove the timing belt rear hood. Refer to Timing Belt Replacement.
3. Remove the coolant pump mounting bolts.
4. Remove the coolant pump from the cylinder block.
5. Remove the ring seal from the coolant pump.

1. Install a new ring seal to the coolant pump.
2. Coat the sealing surface of the ring seal with Lubriplate®.
3. Install the coolant pump to the engine block.
4. Secure the coolant pump to the engine block with the mounting bolts. Tighten: Tighten the coolant pump mounting bolts to 10 N.m (89 lb in).
5. Install the rear timing belt rear hood. Refer to Timing Belt Replacement.
6. Refill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .

1. Disconnect the negative battery cable.
2. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
3. Remove the rear timing belt cover. Refer to «Timing Belt Cover Replacement»(ref-300885-S29545088172008101600000) for the 1.6L (L91) engine.
4. Remove the coolant pump mounting bolts.
5. Remove the coolant pump.
6. Remove the seal ring from the coolant pump.

1. Install a new seal ring to the coolant pump.
2. Coat the sealing surface of the seal ring with Lubriplater®.
3. Install the coolant pump to the engine block with the flange aligned with the recess of the rear timing belt cover. NOTE: Refer to «Fastener Notice»(ref-300819-S01593840602008101600000) .
4. Install the coolant pump mounting bolts. Tighten: Tighten the coolant pump mounting bolts to 10 N.m (89 lb in).
5. Install the rear timing belt cover. Refer to «Timing Belt Cover Replacement»(ref-300885-S29545088172008101600000) for the 1.6L (L91) engine.
6. Fill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
7. Connect the negative battery cable.

1. Drain the engine coolant to below the level of the surge tank.
2. Loosen the overflow hose clamps and disconnect the overflow hose from the top of the surge tank.
3. Remove the tank attaching nuts.
4. Remove the tank from the vehicle.
5. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
6. Rinse the surge tank and the cap thoroughly.

1. Install the surge tank to the vehicle.
2. Secure the surge tank with the attaching nuts. Tighten: Tighten the surge tank attaching nuts to 10 N.m (89 lb in).
3. Connect the overflow hose to the surge tank.
4. Secure the overflow hose to the surge tank with the hose clamps.
5. Fill the surge tank with the coolant to the center ridge, or to the MAX mark.

1. Disconnect the negative battery cable.
2. Disconnect the cooling fan electrical connector(s).
3. Remove the electric cooling fan mounting bolts.
4. Remove the electric cooling fan.

1. Install the electric cooling fan(s).
2. Install the electric cooling fan mounting bolts. Tighten: Tighten the electrical cooling fan mounting bolts to 4 N.m (35 lb in).
3. Connect the cooling fan electrical connector.

1. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
2. Disconnect the upper radiator hose.
3. Remove the thermostat bolts (2).
4. Remove the thermostat housing (3).
5. Remove the thermostat with the gasket (1).
6. Inspect the gasket for cracks or other damage.
7. Inspect the valve seat for foreign matter that could prevent the valve from seating properly.
8. Clean the thermostat housing and mating surface.

1. Position the gasket and install the thermostat and the housing with the bolts (1). Tighten: Tighten the mounting bolts to 20 N.m (15 lb ft).
2. Secure the upper radiator hose to the thermostat housing with a hose clamp.
3. Refill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
2. Remove the timing belt rear hood. Refer to Timing Belt Replacement.
3. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
4. Disconnect the upper radiator hose from the thermostat housing.
5. Remove the mounting bolts that hold the thermostat housing to the cylinder head.
6. Remove the thermostat housing from the cylinder head.
7. Remove the thermostat from its recess in the cylinder head.
8. Inspect the valve seat for foreign matter that could prevent the valve from sealing properly.
9. Clean the thermostat housing and the cylinder head mating surfaces.

1. Install the thermostat into the cylinder head recess.
2. Install the thermostat housing.
3. Secure the thermostat housing to the cylinder head with the mounting bolts. Tighten: Tighten the thermostat housing mounting bolts to 20 N.m (15 lb ft).
4. Install the timing belt rear hood. Refer to Timing Belt Replacement.
5. Connect the upper radiator hose to the thermostat housing.
6. Secure the upper radiator hose to the thermostat housing with a hose clamp.
7. Refill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .

1. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
2. Disconnect the upper radiator hose from the thermostat housing.
3. Disconnect the throttle body coolant inlet hose from the thermostat housing.
4. Remove the thermostat bolts.
5. Remove the thermostat housing.
6. Remove the thermostat with the gasket.
7. Inspect the gasket for cracks or other damage.
8. Inspect the valve seat for foreign matter that could prevent the valve from seating properly.
9. Clean the thermostat housing and mating surface.

1. Install the thermostat with the bolts and the thermostat housing. Tighten: Tighten the mounting bolts to 20 N.m (15 lb ft).
2. Secure the upper radiator hose to the thermostat housing with a hose clamp.
3. Connect the throttle body coolant inlet hose to the thermostat housing.
4. Refill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .

1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
3. Remove the electric cooling fans. Refer to «Engine Cooling Fan Replacement»(ref-300853-S31743481422008101600000) .
4. Remove the upper radiator hose clamp.
5. Disconnect the upper radiator hose from the radiator.
6. Disconnect the lower radiator hose from the radiator.
7. Remove the lower radiator hose clamp.
8. Remove the hose clamp from the surge tank hose at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Remove the left upper radiator retaining bolt.
11. Remove the left upper radiator retaining bracket.
12. Remove the right upper radiator retaining bolt.
13. Remove the right upper radiator retaining bracket.
14. Remove the radiator from the vehicle.

1. Set the radiator into place in the vehicle with the radiator bottom posts in the rubber shock bumpers.
2. Position the radiator retainers in place.
3. Install the upper right radiator retaining bracket.
4. Install the upper right radiator retaining bolt. Tighten: Tighten the upper right radiator retaining bolt to 7 N.m (62 lb in).
5. Install the upper left radiator retaining bracket.
6. Install the upper left radiator retaining bolt. Tighten: Tighten the upper left radiator retaining bolt to 7 N.m (62 lb in).
7. Connect the surge tank hose to the radiator.
8. Secure the surge tank hose with a hose clamp.
9. Connect the upper radiator hose and the lower radiator hose to the radiator.
10. Secure each hose with a hose clamp.
11. Install the electric cooling fans. Refer to «Engine Cooling Fan Replacement»(ref-300853-S31743481422008101600000) .
12. Refill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
13. Connect the negative battery cable.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .
2. Disconnect the coolant heater power supply cord from the coolant heater.
3. Remove the coolant heater and seal from the engine block.

1. Install the seal to the coolant heater.
2. Install the coolant heater in to the engine block. Tighten: Tighten the coolant heater to 60 N.m (44 lb ft).
3. Connect the coolant heater power supply cord to the coolant heater.
4. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-300853-S37390471372008101600000) .

1. Disconnect the coolant heater power supply cord from the coolant heater (2).
2. Disconnect the coolant heater cord clip (1) from the engine lift bracket.
3. Disconnect the coolant heater cord from between the washer bottle and the coolant reservoir (1).
4. Remove the coolant heater cord from the vehicle.

1. Connect the coolant heater cord to the coolant heater (2).
2. Secure the coolant heater cord clip (1) to the engine lift bracket.
3. Route the coolant heater cord along the battery (2).
4. Secure the coiled power cord between the washer fluid bottle and the coolant reservoir (1).