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Engine Cooling System: Removal & Installation Chevrolet HHR I

Cooling System (Mechanical) 12 illustrations ~1994 words

Cooling Fan and Shroud Replacement (LNF)

CalloutComponent Name
Preliminary Procedure Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement . Remove the hood latch from the tie bar and set aside. Refer to Hood Primary and Secondary Latch Replacement . Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement . Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement .
1Engine Cooling Fan and Shroud. Procedure Disconnect the cooling fan motor electrical connector. Remove the transmission line connector from the fan shroud. Lift the radiator out of the support bracket and pull toward the front of the vehicle. Lift up on the fan shroud assembly to release from the radiator.

Scheme 2

Scheme 2: Turbocharger Coolant Feed Pipe Replacement
Scheme 2: Turbocharger Coolant Feed Pipe Replacement
CalloutComponent Name
Preliminary Procedures Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) .
1Turbo Coolant Feed Pipe Fitting (Qty: 2) NOTE: Refer to Fastener Notice . Procedure: Install new gaskets to both banjo bolt fittings. Tighten: 35 N.m (26 lb ft)
2Coolant Feed Pipe Bracket Bolt Tighten: 10 N.m (89 lb in)
3Turbo Cooler Feed Pipe Clip
4Turbocharger Coolant Feed Pipe
NOTE
Refer to Fastener Notice .

Scheme 3

Scheme 3: Turbocharger Coolant Return Pipe Replacement
Scheme 3: Turbocharger Coolant Return Pipe Replacement
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Remove the catalytic converter. Refer to Catalytic Converter Replacement (LE5/L61) or Catalytic Converter Replacement (LNF) .
1Turbo Coolant Feed Pipe Fitting (Qty: 2) NOTE: Refer to Fastener Notice . Procedure: Install new gaskets to both banjo bolt fittings. Tighten: 35 N.m (26 lb ft)
2Turbocharger Coolant Return Pipe
NOTE
Refer to Fastener Notice .

Scheme 4

Scheme 4: Engine Coolant Thermostat Housing Replacement (LNF)
Scheme 4: Engine Coolant Thermostat Housing Replacement (LNF)
CalloutComponent Name
Preliminary Procedures Remove the thermostat. Refer to Engine Coolant Thermostat Replacement (LNF) or Engine Coolant Thermostat Replacement (L61, LE5) . Remove the exhaust manifold. Refer to Exhaust Manifold Heat Shield Replacement . Disconnect the inlet and outlet heater hoses. Refer to Heater Inlet Hose Replacement (LE5, L61) , Heater Inlet Hose Replacement (LNF) , Heater Outlet Hose Replacement (LE5, L61) or Heater Outlet Hose Replacement (LNF) . Remove the coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement .
1Thermostat Housing Bolt (Qty: 3) NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb ft)
2Thermostat Housing
3Water Inlet Seal Procedure: Use a new seal.
NOTE
Refer to Fastener Notice .

Removal Procedure

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) , «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) or «Cooling System Draining and Filling (Static Fill-LNF)»(ref-299633-S38581770322008092400000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.2L (L61) engine or «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.4L engine.
  3. Remove the air cleaner bracket nuts.
  4. Remove the air cleaner bracket.
  5. Remove the exhaust heat shield studs (2).
  6. Remove the exhaust heat shield (1).
  7. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  8. Lower the vehicle.
  9. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  10. Disconnect the heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.
  11. If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (1).
  12. Remove the ECT sensor.
  13. Reposition the radiator outlet hose clamp at the thermostat housing.
  14. Remove the radiator outlet hose from the thermostat housing.
  15. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  16. Disconnect the heater inlet and outlet hoses from the thermostat housing pipes.
  17. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
  18. Remove the thermostat housing bolts.
  19. Remove the thermostat housing from the vehicle.
  20. Remove the water transfer pipe from the thermostat housing, if necessary.
  21. Remove and discard the water transfer pipe O-ring seals, if necessary.
  22. Remove the thermostat housing cover bolts and cover, if necessary.
  23. Remove the thermostat, if necessary.
  24. Remove and discard the thermostat housing O-ring seal, if necessary.
  25. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

Installation Procedure

  1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
  2. Install the thermostat, if necessary.
  3. Install the thermostat housing cover bolts, if necessary. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install a NEW thermostat housing to engine gasket onto the thermostat housing.
  5. Load the thermostat housing assembly into position.
  6. Install NEW O-ring seals onto the water feed pipe.
  7. Install the water feed pipe into the thermostat housing aligning locator tab.
  8. Align the water pipe to water pump.
  9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  10. Position the thermostat housing against the engine.
  11. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  12. Lower the vehicle.
  13. Connect the heater inlet and outlet hoses to the thermostat housing pipes.
  14. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
  15. Install the radiator outlet hose to the thermostat housing.
  16. Position the radiator outlet hose clamp at the thermostat housing.
  17. If reinstalling the old sensor, coat the threads with sealant. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-299639-S13806737202008092400000) .
  18. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  19. If equipped with a manual transaxle, connect the ECT sensor electrical connector (1).
  20. If equipped with a automatic transaxle, perform the following steps, connect the ECT sensor electrical connector (1).
  21. Connect the HO2S electrical connector clip to the thermostat housing.
  22. Verify the drain valves at the radiator and water pump are closed.
  23. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) , «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) or «Cooling System Draining and Filling (Static Fill-LNF)»(ref-299633-S38581770322008092400000) .
  24. Lower the vehicle.
  25. Install the exhaust heat shield (2).
  26. Install the exhaust heat shield studs (1). Tighten: Tighten the studs to 22 N.m (16 lb ft).
  27. Install the air cleaner bracket.
  28. Install the air cleaner bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  29. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.2L (L61) engine or «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.4L engine.
  30. Verify the repair and inspect for any leaks.

Scheme 5

Scheme 5: Engine Coolant Thermostat Replacement (LNF)
Scheme 5: Engine Coolant Thermostat Replacement (LNF)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Disconnect the engine oil cooler hose from the water inlet assembly. Refer to Engine Oil Cooler Hose/Pipe Replacement . Disconnect the radiator outlet hose from the water inlet assembly. Refer to Radiator Outlet Hose Replacement (LE5, L61) or Radiator Outlet Hose Replacement (LNF) .
1Water Inlet Assembly Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
2Water Inlet Assembly
3Engine Coolant Thermostat
NOTE
Refer to Fastener Notice .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) , «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) or «Cooling System Draining and Filling (Static Fill-LNF)»(ref-299633-S38581770322008092400000) .
  2. Reposition the radiator outlet hose clamp at the thermostat housing.
  3. Remove the radiator outlet hose from the thermostat housing.
  4. Remove the thermostat housing cover bolts and cover.
  5. Remove the thermostat.
  6. Remove and discard the thermostat housing O-ring seal.
  1. Install a NEW thermostat housing cover O-ring seal.
  2. Install the thermostat.
  3. Install the thermostat housing cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install the radiator outlet hose to the thermostat housing.
  5. Position the radiator outlet hose clamp at the thermostat housing.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) , «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) or «Cooling System Draining and Filling (Static Fill-LNF)»(ref-299633-S38581770322008092400000) .

Water Pump Replacement (L4)

Tools Required

  1. J 25025-5 Dial Indicator Mounting Post
  2. J 43651 Water Pump Holding Tool. See «Special Tools»(ref-299633-S02913904972008092400000) .
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-474051-S20727948762012051800000) .
  2. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement»(ref-474066-S23912339112012051800000) .
  3. If equipped, remove the coolant heater. Refer to Remove the coolant heater. Refer to «Coolant Heater Replacement (L61, LE5)»(ref-299633-S30490455572008092400000) ..
  4. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LE8, LE9)»(ref-474066-S31743230702012051800000) .
  5. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-299633-S27925574912008092400000) or «Engine Coolant Thermostat Housing Replacement (L61, LE5)»(ref-299633-S42934985402008092400000) .
  6. Remove the water pump cover (2), fasteners (3) and gasket (1) from the engine front cover.
  7. Drain the coolant from the water pump using the plug at the bottom of the pump. Install the plug when finished.
  8. Align the EN-43651 water pump holding tool (1) with the threads on the water pump sprocket. Tighten the water pump holding tool fasteners (2).
  9. Secure the water pump holding tool with the previously removed water pump cover fasteners (1) into the engine front cover.
  10. Remove the water pump sprocket to water pump fasteners (1).
  11. Remove the front water pump fasteners (1).
  12. Remove the rear water pump fasteners (1).
  13. Remove the water pump (1).
  14. If replacing the water pump cover remove the water pump rear cover fasteners (4).
  15. Separate the water pump cover (1) from the water pump (3)
  16. Remove and discard the water pump O-ring seal (2).
  1. If replacing the water pump cover (1), install a new O-ring (2) to the water pump (3) and tighten the fasteners (4) to 25 N.m (18 lb ft)
  2. Using a guide pin (2), align the pin with the water pump holding tool.
  3. Position the water pump (1) against the engine block and hand tighten the water pump fasteners (3).
  4. Install 2 water pump sprocket to water pump fasteners (1). After the fasteners are snug, remove the guide pin (2) and install the 3rd Fastener (3) and tighten to 10 N.m (89 lb in).
  5. Install the water pump fasteners (1) at the front of the engine. Hand tighten at this time.
  6. Tighten the water pump fasteners at the front and rear of the water pump to 25 N.m (18 lb ft).
  7. Remove the water pump cover fasteners (1) from the engine front cover and water pump holding tool.
  8. Remove the EN-43651 water pump holding tool (1) from the water pump sprocket.
  9. Install the water pump access plate (2) gasket (1) and fasteners (3) and tighten to 10 N.m (89 lb in).
  10. Install the coolant heater, if equipped. Refer to «Coolant Heater Replacement (LNF)»(ref-299633-S31871133342008092400000) .
  11. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (L61, LE5)»(ref-299633-S42934985402008092400000) .
  12. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LE8, LE9)»(ref-474066-S31743230702012051800000)
  13. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement»(ref-474066-S23912339112012051800000) .
  14. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-474051-S20727948762012051800000) .
  15. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) , «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) or «Cooling System Draining and Filling (Static Fill-LNF)»(ref-299633-S38581770322008092400000) .
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299613-S26723263942008092400000) .
  2. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-299633-S27925574912008092400000) or «Engine Coolant Thermostat Housing Replacement (L61, LE5)»(ref-299633-S42934985402008092400000) .
  3. Remove the water pump access plate from the front cover.
  4. Drain the coolant from the water pump using the plug at the bottom of the pump.
  5. Install the J 43651 (1) into position. See «Special Tools»(ref-299633-S02913904972008092400000) .
  6. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  7. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  8. Remove the 3 inner water pump sprocket to water pump blots.
  9. Remove the 2 water pump bolts.
  10. Remove the rear 2 water pump bolts.
  11. Remove the water pump.
  12. Remove and discard the water pump O-ring seal.
  1. Install a NEW water pump O-ring seal.
  2. Using the guide pin, align the pin with the water pump holding tool.
  3. Position the water pump against the engine block and hand tighten the water pump bolts.
  4. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  5. Tighten the water pump sprocket bolts last. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  6. Remove the J 43651 (1). See «Special Tools»(ref-299633-S02913904972008092400000) .
  7. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-299633-S27925574912008092400000) or «Engine Coolant Thermostat Housing Replacement (L61, LE5)»(ref-299633-S42934985402008092400000) .
  9. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299613-S26723263942008092400000) .

Radiator Drain Cock Replacement

CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-299584-S01107113332008092400000) .
  2. Place a drain pan under the right side lower radiator mount.
  3. Remove the radiator drain cock.
  1. Install the radiator drain cock. Tighten the radiator drain cock by hand only.
  2. Lower the vehicle.
  3. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LE5, L61)»(ref-299633-S28287530232008092400000) , «Cooling System Draining and Filling (GE 47716 Fill)»(ref-299633-S22326301682008092400000) or «Cooling System Draining and Filling (Static Fill-LNF)»(ref-299633-S38581770322008092400000) .

Scheme 6

Scheme 6: Fan Shroud Replacement
Scheme 6: Fan Shroud Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Remove the fan shroud assembly. Refer to Cooling Fan and Shroud Replacement (LE5, L61) or Cooling Fan and Shroud Replacement (LNF) .
1Nut, Engine Cooling Fan Blade Tighten: 6 N.m (53 lb in)
2Blade, Fan
3Bolt, Engine Cooling Fan Motor (Qty: 3) Tighten: 6 N.m (53 lb in)
4Motor Assembly, Engine Cooling Fan
5Shroud, Engine Cooling Fan
NOTE
Refer to Fastener Notice .

Scheme 7

Scheme 7: Radiator Replacement
Scheme 7: Radiator Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 2.2L engine or Air Cleaner Assembly Replacement for the 2.4L engine. Remove the hood latch from the tie bar and set aside. Refer to Hood Primary and Secondary Latch Replacement . Remove the transmission lines from the radiator. Refer to Automatic Transmission Oil Cooler Pipes Replacement . Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement . Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LE5, L61) or Radiator Outlet Hose Replacement (LNF) .
1Bolt, Radiator Bracket Assembly Tighten: 9 N.m (80 lb in)
2Bracket Assembly, Radiator
3Radiator Assembly Tip: Lift up on the fan assembly and remove from the radiator and set a side. Push in on the retaining tabs to release the condenser from the radiator and set aside.
NOTE
Refer to Fastener Notice .

Scheme 8

Scheme 8: Radiator Support Bracket Replacement
Scheme 8: Radiator Support Bracket Replacement
CalloutComponent Name
1Radiator Bracket Assembly Bolt - Upper NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Radiator Bracket Asm - Upper
NOTE
Refer to Fastener Notice .

Scheme 9

Scheme 9: Radiator Support Replacement (L61, LE5)
Scheme 9: Radiator Support Replacement (L61, LE5)
CalloutComponent Name
Preliminary Procedure: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Front Bumper Fascia Lower Deflector Retainer- Push In
2Radiator Support Bolt - Lower NOTE: Refer to Fastener Notice . Tighten: 22 N.m (16 lb ft)
3Radiator Support - Lower
NOTE
Refer to Fastener Notice .

Radiator Support Replacement (LNF)

CalloutComponent Name
Preliminary Procedure: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Front Bumper Fascia Lower Deflector Retainer - Push In
2Radiator Support Bolt - Lower NOTE: Refer to Fastener Notice . Tighten: 34 N.m (25 lb ft)
3Radiator Support - Lower
NOTE
Refer to Fastener Notice .

Scheme 10

Scheme 10: Radiator Air Side Baffle and Deflector Replacement
Scheme 10: Radiator Air Side Baffle and Deflector Replacement
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .
1Radiator Air Baffle and Deflector- Side Tip: Pull up and the out to release the radiator air seal from the radiator. Right side shown left similar.

Scheme 11

Scheme 11: Radiator Air Upper Baffle and Deflector Replacement
Scheme 11: Radiator Air Upper Baffle and Deflector Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .
1Radiator Bracket Assembly- Upper Bolt Tighten: 9 N.m (80 lb in)
2Radiator - Upper Bracket Assembly
3Radiator Air Baffle and Deflector- Upper
NOTE
Refer to Fastener Notice .

Scheme 12

Scheme 12: Coolant Heater Replacement (LNF)
Scheme 12: Coolant Heater Replacement (LNF)
CalloutComponent Name
Preliminary Procedure: Remove the turbocharger assembly. Refer to Turbocharger Replacement .
1Coolant Heater Bolt NOTE: Refer to Fastener Notice . Procedure: Disconnect the electrical connector. Tighten: 10 N.m (89 lb in)
2Coolant Heater
NOTE
Refer to Fastener Notice .
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.2L (L61) engine or «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.4L engine.
  2. Disconnect the coolant heater cord.
  3. Remove the coolant heater bolt.
  4. Remove the coolant heater.
  1. Install the coolant heater.
  2. Install the coolant heater bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Connect the coolant heater cord.
  4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.2L (L61) engine or «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.4L engine.

Scheme 13

Scheme 13: Coolant Heater Cord Replacement (LNF)
Scheme 13: Coolant Heater Cord Replacement (LNF)
CalloutComponent Name
1Coolant Heater Plastic Retainer (Qty: 3) Procedure: Disconnect the electrical connectors.
2Coolant Heater Cord
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.2L (L61) engine or «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.4L engine.
  2. Disconnect the engine coolant heater cord.
  3. If equipped with regular production option (RPO) L61 and a manual transaxle, remove the cord clips (1) from the camshaft cover.
  4. If equipped with RPO LE5, or RPO L61 and a automatic transaxle, disconnect the straps from the engine harness.
  5. Disconnect the strap from the right front headlamp harness.
  6. Remove the heater cord.
  1. Install the heater cord.
  2. Connect the strap to the right front headlamp harness.
  3. If equipped with RPO LE5, or RPO L61 and a automatic transaxle, connect the straps to the engine harness.
  4. If equipped with RPO L61 and a manual transaxle, install the cord clips (1) to the camshaft cover.
  5. Connect the engine coolant heater cord.
  6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.2L (L61) engine or «Air Cleaner Assembly Replacement»(ref-299614-S34823254312008092400000) for the 2.4L engine.

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