Engine Cooling System Chevrolet Malibu VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Cooling System Connector End Views

Coolant Level Switch Connector End Views Connector Part Information 12052641 2-Way F Metri-Pack 150 Series Sealed (BK) Pin Wire Color Circuit No. Function A BK 350 Ground B L-GN 1478 Coolant Level Switch Signal

Cooling Fan Connector End Views- Left Connector Part Information 12033769 2-Way F Metri-Pack 630 Series Sealed Pull-to-Seat (BK) Pin Wire Color Circuit No. Function A WH 504 Cooling Fan Motor Low Reference B L-BU 409 Cooling Fan Motor Supply Voltage 1

Cooling Fan Connector End Views - Right Connector Part Information 12033769 2-Way F Metri-Pack 630 Series Sealed Pull-to-Seat (BK) Pin Wire Color Circuit No. Function A BK 450 Ground B GY 532 Cooling Fan Motor Supply Voltage 2

Diagnostic Starting Point - Engine Cooling

Begin the system diagnosis with the Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check in Vehicle DTC Information will provide the following information

1. The identification of the control module(s) which command the system.
2. The ability of the control module(s) to communicate through the serial data circuit.
3. The identification of any stored diagnostic trouble codes (DTCs) and their status.

The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located.

Scan Tool Output Controls

Powertrain Control Module (PCM) Scan Tool Output Controls, LX9 / 3.5L only

Scan Tool Data List

Powertrain Control Module (PCM) Scan Tool Data List, 3.5L / LX9

Powertrain Control Module (PCM) Scan Tool Data List, 2.2L / L61

Circuit Description

The powertrain control module (PCM) controls the low speed cooling fan operation by grounding the low speed fan relay control circuit with an internal solid state device called a driver. For high speed cooling fan operation, the PCM grounds the high speed and S/P relay control circuit at the same time the low speed control circuit is grounded. Battery positive voltage is supplied to the low speed, high speed and S/P fan relays. When the PCM is commanding a fan relay ON, the voltage of the control circuit should be low, near 0 volts. When the PCM is commanding a fan relay OFF, the voltage potential of the control circuit should be high, near battery voltage. If the fault detection circuit senses a voltage other than what is expected, the DTC will set. The vehicle has DTCs which include DTC Symptoms. For more information on DTC Symptoms, refer to DTC Symptom Description in Vehicle DTC Information.

If the PCM detects an improper voltage level on the low or high speed driver circuits, then code P0480, P0481, P0691, P0692, P0693, or P0694, will set and the effected driver will be disabled.

1. P0480 - Cooling Fan Relay 1 Control Circuit
2. P0481- Cooling Fan Relays 2 and 3 Control Circuit
3. P0691 - Cooling Fan Relay 1 Control Circuit Low Voltage
4. P0692 - Cooling Fan Relay 1 Control Circuit High Voltage
5. P0693 - Cooling Fan Relay 2 and 3 Control Circuit Low Voltage
6. P0694 - Cooling Fan Relay 2 and 3 Control Circuit High Voltage

The P0694 condition is present for 1 second.

Conditions for Running the DTC

1. The ignition voltage is between 9.0-18.0 volts.
2. The engine speed is more than 40 RPM.
3. The PCM driver transitions from ON to OFF or from OFF to ON.

Action Taken When the DTC Sets

1. The PCM will illuminate the malfunction indicator lamp (MIL) during the second consecutive trip in which the diagnostic test has been run and failed.
2. The PCM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.

Conditions for Clearing the MIL/DTC

1. The PCM will turn OFF the MIL during the third consecutive trip in which the diagnostic has been run and passed.
2. The History DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
3. Use the scan tool Clear DTC Information function.

Diagnostic Aids

1. If the condition is not present, refer to «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2003-2006/remont/body-electrical/#wiring-systems-specifications-component-views-and-connector-end-views__testing-for-intermittent-conditions-and-poor) in Wiring Systems.
2. Review the Freeze/Failure Records vehicle mileage since the diagnostic test failed. This may help determine how often the condition that caused the DTC to be set occurs.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 2: Listen for an audible click when the cool fan relay 1 operates. Command both the ON and OFF states. Repeat the commands as necessary.
2. 3: Listen for an audible click when the S/P and cool fan 2 relays operate. Command both the ON and OFF states. Repeat the commands as necessary.

DTC P0480, P0481, P0691, P0692, P0693, or P0694 (LX9)

The powertrain control module (PCM) controls the low speed cooling fan operation by grounding the low speed fan relay control circuit with an internal solid state device called a driver. For high speed cooling fan operation, the PCM grounds the high speed and S/P relay control circuit at the same time the low speed control circuit is grounded. Battery positive voltage is supplied to the low speed, high speed and S/P fan relays. When the PCM is commanding a fan relay ON, the voltage of the control circuit should be low, near 0 volts. When the PCM is commanding a fan relay OFF, the voltage potential of the control circuit should be high, near battery voltage. If the fault detection circuit senses a voltage other than what is expected, the DTC will set. The vehicle has DTCs which include DTC Symptoms. For more information on DTC Symptoms, refer to DTC Symptom Description in Vehicle DTC Information.

If the PCM detects an improper voltage level on the low or high speed driver circuits, then code P0480, P0481, P0691, P0692, P0693, or P0694, will set and the effected driver will be disabled.

1. P0480 - Cooling Fan Relay 1 Control Circuit
2. P0481- Cooling Fan Relays S/P and Relay 2 Control Circuit
3. P0691 - Cooling Fan Relay 1 Control Circuit Low Voltage
4. P0692 - Cooling Fan Relay 1 Control Circuit High Voltage
5. P0693 - Cooling Fan Relay 2 Control Circuit Low Voltage
6. P0694 - Cooling Fan Relays S/P and Relay 2 Control Circuit High Voltage

The P0694 condition is present for 1 second.

1. The ignition voltage is between 9.0-18.0 volts.
2. The engine speed is more than 40 RPM.
3. The PCM driver transitions from ON to OFF or from OFF to ON.

1. The PCM will illuminate the malfunction indicator lamp (MIL) during the second consecutive trip in which the diagnostic test has been run and failed.
2. The PCM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.

1. The PCM will turn OFF the MIL during the third consecutive trip in which the diagnostic has been run and passed.
2. The History DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
3. Use the scan tool Clear DTC Information function.

1. If the condition is not present, refer to «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2003-2006/remont/body-electrical/#wiring-systems-specifications-component-views-and-connector-end-views__testing-for-intermittent-conditions-and-poor) in Wiring Systems.
2. Review the Freeze/Failure Records vehicle mileage since the diagnostic test failed. This may help determine how often the condition that caused the DTC to be set occurs.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: Listen for an audible click when the cool fan relay 1 operates. Command both the ON and OFF states. Repeat the commands as necessary.
2. 3: Listen for an audible click when the S/P and cool fan 2 relays operate. Command both the ON and OFF states. Repeat the commands as necessary.

DTC P0480, P0481, P0691, P0692, P0693, or P0694 (L61)

The powertrain control module (PCM) uses the engine coolant temperature (ECT) sensor to monitor the engine for an over temperature condition. This condition occurs when the coolant temperature is above 128°C (262°F). When an over temperature condition is present, DTC P1258 will set. The PCM will disable 2 groups of cylinders by turning OFF the fuel injectors. By switching between the 2 groups of cylinders, the PCM is able to reduce the temperature of the coolant.

The ignition is ON.

Conditions for Setting the DTC

1. The PCM detects an engine metal over temperature.
2. The above condition is present for at least 8 seconds.

1. The PCM will illuminate the malfunction indicator lamp (MIL) during the first trip in which the diagnostic test has been run and failed.
2. The PCM will signal the instrument panel cluster (IPC) to turn ON the Service Engine Soon indicator.
3. The PCM will alternately disable 2 groups of cylinders by turning OFF the fuel injectors.
4. The PCM will store conditions which were present when the DTC set as Freeze Frame and File Records data.
5. A history DTC is stored.

1. The PCM will turn the MIL OFF after 3 consecutive trips that the diagnostic has been run and passed.
2. The history DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
3. The DTC can be cleared by using the scan tool Clear DTC Information function.

DTC P1258

Symptoms - Engine Cooling

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the Cooling System. Refer to «Checking Aftermarket Accessories»(/chevrolet/malibu/vi-2003-2006/remont/body-electrical/#wiring-systems-specifications-component-views-and-connector-end-views__checking-aftermarket-accessories) in Wiring Systems.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Inspect the surge tank reservoir for the proper coolant level.

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Engine Coolant Temperature Indicator Always On»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__engine-coolant-temperature-indicator-always-on)
2. «Low Engine Coolant Indicator Always On»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__low-engine-coolant-indicator-always-on)
3. «Cooling Fan Always On»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__cooling-fan-always-on)
4. «Cooling Fan Inoperative (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__cooling-fan-inoperative-lx9) or «Cooling Fan Inoperative (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__cooling-fan-inoperative-l61)
5. «Engine Overheating»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__engine-overheating)
6. «Loss of Coolant»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__loss-of-coolant)
7. «Thermostat Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system)
8. «Coolant Heater Inoperative»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__coolant-heater-inoperative)
9. «Engine Fails To Reach Normal Operating Temperature»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__engine-fails-to-reach-normal-operating)

Engine Coolant Temperature Indicator Always On

Engine Coolant Temperature Indicator Always On

Low Engine Coolant Indicator Always On

Low Engine Coolant Indicator Always On

Cooling Fan Always On

Cooling Fan Always On

Cooling Fan Inoperative (LX9)

Cooling Fan Inoperative (LX9)

Cooling Fan Inoperative (L61)

Cooling Fan Inoperative (L61)

Engine Overheating

Engine Overheating

Loss of Coolant

Loss of Coolant

Thermostat Test Procedure Using Glycol

Inspect the operation of the thermostat by hanging the thermostat on a hook in a 33 percent glycol solution.

In order to inspect if the thermostat valve is opening properly, perform the following test

1. Completely submerge the thermostat in a glycol solution. The solution should be 11°C (22°F) above the temperature indicated on the thermostat valve.
2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should open.

In order to inspect if the thermostat valve is closing properly, perform the following test

1. Completely submerge the thermostat in a glycol solution. The solution should be 6°C (10°F) below the temperature indicated on the thermostat valve.
2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should close completely.

Coolant Heater Inoperative

Coolant Heater Inoperative

Engine Fails To Reach Normal Operating Temperature

Engine Fails To Reach Normal Operating Temperature

Pressure Cap Testing

Tools Required

1. J 24460-01 Cooling System Pressure Tester. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Test the pressure cap for the following conditions: Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) . Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions: The pressure cap does not release pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

Cooling System Leak Testing

Tools Required

1. J 24460-01 Cooling System Pressure Tester. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. J 42401 Radiator Cap / Surge Tank Test Adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

1. Remove the pressure cap.
2. Test the operation of the pressure cap. Refer to «Pressure Cap Testing»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__pressure-cap-testing) .
3. Wash the pressure cap mating surface with water.
4. Use the J 24460-01 with J 42401 in order to apply pressure to the cooling system. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) . Do not exceed the pressure cap rating.
5. The cooling system should hold the rated pressure for at least 2 minutes. Observe the gage for any pressure loss.
6. Repair any leaks as required.

Tools Required

J 26568 Coolant and Battery Fluid Tester. See Special Tools and Equipment .

Draining Procedure

1. Unscrew the surge tank cap to remove vacuum when draining coolant.
2. Place a container under the radiator drain.
3. Unscrew the radiator drain plug until coolant flows out of the radiator drain.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Place a container under the water pump housing and open the water pump drain plug.
6. Follow the appropriate procedure based on the condition of coolant. Normal in appearance-Follow filling procedure. Discolored-Follow flush procedure. Refer to «Flushing (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__flushing-l61) and «Flushing (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__flushing-lx9) .

Fill Procedure

1. Close the radiator drain plug.
2. Close the water pump drain plug. Refer to «Water Pump Installation»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__water-pump-installation) in Engine Mechanical - 2.2L.
3. Lower the vehicle.
4. Vehicle should be level.
5. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Capacities - Approximate Fluid»(/chevrolet/malibu/vi-2003-2006/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) in Maintenance and Lubrication.
6. Install the surge tank cap.
7. Start the engine and run at 2,000 RPM until the engine cooling fans turn ON.
8. Remove the surge tank cap.
9. Refill to the weld seam on the surge tank.
10. Install the surge tank cap.
11. Inspect the concentration of engine coolant using J 26568 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
12. Rinse away any excess coolant from the engine and the engine compartment.

J 26568 Coolant and Battery Fluid Tester. See Special Tools and Equipment .

Scheme 5

1. Unscrew the surge tank cap to remove vacuum when draining coolant.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Place a container under the radiator drain.
4. Unscrew the radiator drain plug until coolant flows out the radiator drain.
5. Place a large pan under the engine block left coolant drain plug and remove the drain plug.
6. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «Flushing (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__flushing-l61) and «Flushing (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system__flushing-lx9) .

1. Install the engine block left coolant drain plug. Refer to «Engine Block Assemble»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L.
2. Close the radiator drain plug.
3. Lower the vehicle.
4. Vehicle should be level.
5. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Capacities - Approximate Fluid»(/chevrolet/malibu/vi-2003-2006/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) in Maintenance and Lubrication.
6. Unscrew the coolant bleed screw on the engine until coolant comes out of the bleed screw.
7. Close the bleed screw.
8. Add coolant until the level stabilizes at the weld seam on the surge tank.
9. Install the surge tank cap.
10. Start the engine and run at 2,000 RPM until the engine cooling fans turn ON.
11. Remove the surge tank cap.
12. Refill to the weld seam on the surge tank.
13. Install the surge tank cap.
14. Inspect the concentration of the engine coolant using J 26568 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
15. Rinse away any excess coolant from the engine and the engine compartment.

Flushing (L61)

1. Apply the park brake.
2. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Fill the coolant system with clean drinkable water. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Start the engine and run at 2,000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
9. Add 0.5 liters (0.13 gal) of concentrated antifreeze since there will be some water in the system.
10. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

Flushing (LX9)

1. Apply the park brake.
2. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Fill the coolant system with clean drinkable water. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Start the engine and run at 2,000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
9. Add 3.8 liters (1.0 gal) of concentrated antifreeze since there will be some water in the system.
10. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

Radiator Cleaning

Note. The radiator fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer.

1. Some conditions may require the use of warm water and a mild detergent.
2. Clean the A/C condenser fins.
3. Clean between the A/C condenser and radiator.
4. Clean the radiator cooling fins.
5. Straighten any damaged cooling fins.

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Removal Procedure

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Remove the surge tank inlet hose from the surge tank.
4. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
5. Disconnect the coolant level sensor wire harness connector.
6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
7. Remove the surge tank outlet hose from the surge tank.
8. Remove the surge tank.

Installation Procedure

1. Install the surge tank outlet hose to the surge tank.
2. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Connect the coolant level sensor wire harness connector.
4. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
5. Press down on the surge tank to engage the mounting tabs.
6. Pull upward on the surge tank to ensure that the tabs are engaged.
7. Install the surge tank inlet hose to the surge tank.
8. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
9. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
10. Install the surge tank cap.

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the surge tank inlet hose from the surge tank.
3. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Remove the surge tank inlet hose from the engine.
5. Remove the surge tank inlet hose clamps from the surge tank inlet hose.

1. Install the surge tank inlet hose clamps to the surge tank hose.
2. Install the surge tank inlet hose to the engine.
3. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Install the surge tank inlet hose to the surge tank.
5. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the surge tank inlet hose from the engine.
3. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Remove the surge tank inlet hose from the surge tank.
5. Remove the surge tank inlet hose clamps from the surge tank inlet hose.

1. Install the surge tank inlet hose clamps to the surge tank inlet hose.
2. Install the surge tank inlet hose to the surge tank.
3. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Install the surge tank inlet hose to the engine.
5. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Reposition the surge tank outlet hose clamp at engine using J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Remove the surge tank outlet hose from the engine.
4. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
5. Remove the surge tank from the surge tank bracket.
6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
7. Remove the surge tank outlet hose from the surge tank.
8. Remove the surge tank outlet hose clamps from the surge tank outlet hose.

1. Install the surge tank outlet hose clamps to the surge tank outlet hose.
2. Install the surge tank outlet hose to the surge tank.
3. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
5. Press down on the surge tank to engage the mounting tabs.
6. Install the surge tank outlet hose to the engine.
7. Reposition the surge outlet hose clamp at the engine using J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
8. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
3. Remove the surge tank from the surge tank bracket.
4. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
5. Remove the surge tank outlet hose from the surge tank.
6. Remove the left headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
8. Remove the surge tank outlet hose from the radiator.
9. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
10. Remove the surge tank outlet hose from the surge tank hose clip.
11. Remove the surge tank outlet hose clamps from the surge tank outlet hose.

1. Install the surge tank outlet hose clamps to the surge tank outlet hose.
2. Install the surge tank outlet hose to the surge tank hose clip.
3. Lower the vehicle.
4. Install the surge tank outlet hose to the radiator.
5. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Install the left headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
7. Install the surge tank outlet hose to the surge tank.
8. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
9. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
10. Press down on the surge tank to engage the mounting tabs.
11. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Remove the radiator inlet hose from the radiator.
5. Reposition the radiator inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Remove the radiator inlet hose at the engine.
7. Remove the radiator inlet hose clamps from the radiator inlet hose.

1. Install the radiator inlet hose clamps to the radiator inlet hose.
2. Install the radiator inlet hose to the engine.
3. Reposition the radiator inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Install the radiator inlet hose to the radiator.
5. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
7. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Remove the radiator inlet hose from the radiator.
5. Reposition the radiator inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Remove the radiator inlet hose from the engine.
7. Remove the radiator inlet hose clamps from the radiator inlet hose.

1. Install the radiator inlet hose clamps to the radiator inlet hose.
2. Install the radiator inlet hose to the engine.
3. Reposition the radiator inlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Install the radiator inlet hose to the radiator.
5. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
7. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Remove the radiator outlet hose from the radiator.
4. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
5. Remove the radiator outlet hose from the engine.
6. Remove the radiator outlet hose clamps from the radiator outlet hose.

1. Install the radiator outlet hose clamps to the radiator outlet hose.
2. Install the radiator outlet hose to the engine.
3. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Install the radiator outlet hose to the radiator.
5. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L (LX9).
3. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Remove the radiator outlet hose from the engine.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
7. Remove the right radiator air deflector retainers.
8. Remove the right radiator air deflector.
9. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
10. Remove the radiator outlet hose from the radiator.
11. Remove the radiator outlet hose clamps from the radiator outlet hose.

1. Install the radiator outlet hose clamps to the radiator outlet hose.
2. Install the radiator outlet hose to the radiator.
3. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Install the right radiator air deflector.
5. Install the right radiator air deflector retainers.
6. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
7. Lower the vehicle.
8. Install the radiator outlet hose to the engine.
9. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
10. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L (LX9).
11. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

1. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
2. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Unclip the upper transmission oil cooler pipe from the fan shroud. Do not disconnect transmission oil cooler pipe from transmission or radiator.
4. Loop a rope around each of the upper 2 tabs on the condenser and tie a rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.
6. Remove the upper radiator support brackets.
7. Pry upward on the fan shroud tabs at the radiator clips.
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
9. Remove the lower radiator air deflector retainers.
10. Remove the lower radiator air deflector.
11. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
12. Remove the right radiator air deflector retainers.
13. Remove the right radiator air deflector.
14. Remove the left radiator air deflector retainers.
15. Remove the left radiator air deflector.
16. Remove the lower radiator support bracket bolts.
17. Remove the lower radiator support brackets.
18. Remove the fan wire harness connectors.
19. Remove the fan shroud assembly.

1. Install the fan shroud assembly.
2. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
3. The radiator air side seals must be in the proper position for proper air flow.
4. Install the lower radiator support brackets.
5. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
6. Install the fan wire harness connectors.
7. Install the left radiator air deflector.
8. Install the left radiator air deflector retainers.
9. Install the right radiator air deflector.
10. Install the right radiator air deflector retainers.
11. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
12. Install the lower radiator air deflector.
13. Install the lower radiator air deflector retainers.
14. Lower the vehicle.
15. Snap the fan shroud tabs into the radiator clips.
16. Remove the rope attached to the condenser and upper tie bar.
17. Install the upper radiator support brackets.
18. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (7 lb ft).
19. Clip the upper transmission oil cooler pipe to the shroud.
20. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
21. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
4. Remove the upper transmission oil cooler pipe from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
5. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
6. Remove the upper radiator support bracket bolts.
7. Remove the upper radiator support brackets.
8. Pry upward on the fan shroud tabs at the radiator clips.
9. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
10. Remove the lower radiator air deflector retainers.
11. Remove the lower radiator air deflector.
12. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
13. Remove the right radiator air deflector retainers.
14. Remove the right radiator air deflector.
15. Remove the left radiator air deflector retainers.
16. Remove the left radiator air deflector.
17. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
18. Remove the radiator outlet hose from the radiator.
19. Remove the fan wire harness connectors.
20. Remove the lower radiator support bracket bolts.
21. Remove the lower radiator support brackets.
22. Place a drain pan under the transmission oil cooler pipes.
23. Remove the transmission oil cooler pipes attachment nut from the transmission.
24. Remove both transmission oil cooler pipes from the transmission.
25. Remove the transmission oil cooler pipe clip from the fan shroud.
26. Remove the lower transmission oil cooler pipe from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
27. Remove the transmission oil cooler pipes.
28. Remove the fan wire harness connectors.
29. Remove the fan shroud assembly.

1. Install the fan shroud assembly.
2. Install the transmission oil cooler pipes.
3. Install the lower transmission oil cooler pipe to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
4. Install the transmission oil cooler pipe clip to the fan shroud.
5. Install both transmission oil cooler pipes to the transmission.
6. Install the transmission oil cooler pipe attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
7. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
8. The radiator air side seals must be in the proper position for proper air flow.
9. Install the lower radiator support brackets.
10. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
11. Install the fan wire harness connectors.
12. Install the radiator outlet hose to the radiator.
13. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
14. Install the left radiator air deflector.
15. Install the left radiator air deflector retainers.
16. Install the right radiator air deflector.
17. Install the right radiator air deflector retainers.
18. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
19. Install the lower radiator air deflector.
20. Install the lower radiator air deflector retainers.
21. Lower the vehicle.
22. Snap fan shroud tabs into the radiator clips.
23. Remove the rope attached to the condenser and upper tie bar.
24. Install the upper radiator support brackets.
25. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
26. Install the upper transmission oil cooler pipe to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
27. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
28. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
29. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
30. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) in Automatic Transaxle - 4T40-E/4T45-E.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
3. Disconnect the surge tank hose from the coolant outlet.
4. Remove the thermostat housing to intake manifold bolts.
5. Remove the thermostat housing outlet and thermostat.

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 25 N.m (18 lb ft).
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
5. Inspect the system for leaks.

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Remove the coolant cap from the surge tank.
2. Place a coolant container under the radiator drain valve at the right hand side of the radiator tank.
3. Using a flat-bladed screwdriver, open the valve and drain the coolant.
4. Raise the vehicle on a hoist.
5. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
6. Lower the vehicle.
7. Disconnect the radiator hose and clamp from the thermostat pipe assembly using the J 38185 , or equivalent. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
8. Disconnect the surge tank return hose and clamp from the thermostat housing pipe.
9. Remove the attachment bolt from the thermostat bracket assembly to thermostat pipe assembly near the front of the engine.
10. Remove the exhaust heat shield bolts.
11. Remove the exhaust heat shield.
12. Disconnect the electrical connector at the coolant temperature sensor.
13. Disconnect the O2 sensor connector and clip from the bracket.
14. Disconnect the heater inlet and outlet hoses and clamps at the thermostat housing pipes.
15. Remove the thermostat housing bolts to the engine.
16. Remove the water transfer pipe from the thermostat housing.
17. Remove the thermostat housing assembly from the vehicle.
18. Remove the water transfer pipe O-seals and discard.
19. Remove the thermostat housing cover bolts and cover.
20. Remove and discard the thermostat housing O-seal.
21. Remove the thermostat cartridge and inner sleeve from the thermostat housing.
22. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

1. Install the thermostat cartridge into the thermostat housing while aligning the cartridge tangs up with the thermostat housing bolt holes. This will assure the inner sleeve can be completely installed.
2. Align and insert the inner sleeve notch into the thermostat housing. If the inner sleeve notch is not properly positioned, the sleeve will not completely seat into the housing.
3. Install a new thermostat housing cover seal into the recess groove.
4. Install the thermostat housing cover bolts. Tighten: Tighten the thermostat housing cover-to-thermostat housing bolts to 10 N.m (89 lb in).
5. Install a new thermostat housing to engine seal onto the thermostat housing.
6. Load the thermostat housing assembly into position while the vehicle is lowered.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
8. Install new O-seals onto the water feed pipe.
9. Install the water feed pipe into the thermostat housing aligning locator tab.
10. Align the water pipe to water pump.
11. Seat the water feed O-seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
12. Lower the vehicle.
13. Position the thermostat housing against the engine. Be sure that the thermostat housing pipe is properly positioned against the support bracket near the front of the engine.
14. Install the thermostat housing to block bolts. Tighten: Tighten the thermostat housing-to-block bolts to 10 N.m (89 lb in).
15. Install the thermostat pipe bracket-to-engine bolt. Tighten: Tighten the thermostat pipe bracket-to-cylinder head bolt to 8 N.m (71 lb in).
16. Connect the electrical connector to coolant sensor.
17. Connect the O2 sensor connector and re-attach the connector to the bracket.
18. Connect the heater inlet and outlet hoses to the thermostat housing and reposition the clamps.
19. Connect the lower radiator hose and clamp.
20. Connect the surge tank return hose to the thermostat pipe.
21. Install the exhaust manifold heat shield.
22. Install the exhaust manifold shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 23 N.m (17 lb ft).
23. Verify the drain valves at the radiator and water pump are closed.
24. Fill the engine coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
25. Verify the repair and inspect for any leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the thermostat housing to water pump feed pipe bolts.
3. Remove the thermostat housing to water pump feed pipe.
4. Remove the thermostat and retaining sleeve, noting orientation for installation.

1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
2. Install the thermostat housing to water pump feed pipe.
3. Install the thermostat housing to water pump feed pipe bolt. Tighten: Tighten the bolt to 10 N.m (18 lb in).
4. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
3. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
4. Remove the radiator inlet hose from the water outlet housing.
5. Remove the water outlet housing bolts.
6. Remove the water outlet housing.
7. Remove the thermostat.
8. Clean and inspect the water outlet housing gasket mating surfaces.

1. Install the thermostat.
2. Install the water outlet housing.
3. Install the water outlet housing bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the radiator inlet hose to the water outlet housing.
5. Use the J 38185 in order to reposition and install the hose clamp to the water outlet housing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
6. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Carefully remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
3. Remove the spark plug wires at the left bank.
4. Using the J 38185 , reposition the hose clamp at the thermostat housing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
5. Remove the upper radiator hose from the housing.
6. Disconnect the heater outlet hose from the thermostat bypass pipe.
7. Remove the thermostat bypass pipe-to-throttle body nut.
8. Using the J 38185 , reposition the hose clamp at the thermostat bypass pipe. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
9. Disconnect the thermostat bypass pipe hose.
10. Remove the thermostat bypass pipe-to-engine front cover bolt.
11. Remove the thermostat bypass pipe.

Scheme 6

1. Install the thermostat bypass pipe.
2. Install the thermostat bypass pipe-to-engine front cover bolt. Tighten: Tighten the bolt to 11 N.m (98 lb in).
3. Connect the thermostat bypass pipe hose.
4. Using the J 38185 , reposition and secure the hose clamp at the thermostat bypass pipe. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
5. Install the thermostat bypass pipe to the throttle body stud.
6. Install the thermostat bypass pipe-to-throttle body nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
7. Connect the heater outlet hose to the thermostat bypass pipe.
8. Connect the inlet hose at the thermostat housing.
9. Using the J 38185 , reposition and install the inlet hose clamp at the thermostat housing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
10. Install the spark plug wires at the left bank.
11. Install the air cleaner assembly. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
13. Inspect for leaks.

J 43651 Water Pump Holding Tool. See Special Tools and Equipment .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the thermostat housing pipe-to-cylinder bolt near the front of the engine.
3. Remove the exhaust manifold heat shield and bolts.
4. Remove the water pump access plate from the front cover.
5. Remove the right hand wheel nuts and wheel assembly.
6. Remove the right hand inner push-pins and splash shield.
7. Disconnect the engine coolant temperature sensor electrical connector.
8. Drain the coolant from the plug at the bottom of the water pump.
9. Remove the thermostat housing bolts.
10. Move the thermostat housing toward the left hand side of the vehicle while twisting the water feed pipe from the rear of the water pump assembly. Leave the coolant hoses and thermostat housing cover connected.
11. Remove the water feed pipe.
12. Discard the water pipe seals.
13. Install the J 43651 into position. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
14. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
15. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
16. Remove the 3 inner water pump sprocket to water pump blots.
17. Remove the 2 water pump assembly bolts.
18. Remove the rear 2 water pump assembly bolts.
19. Remove the water pump assembly and water pump O-ring seal.

1. Install a new water pump assembly seal.
2. Using the guide pin, align the pin with the water pump holding tool.
3. Position the water pump assembly 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 water pump bolts to 25 N.m (18 lb ft).
5. Tighten the water pump socket bolts last. Tighten: Tighten the water pump sprocket-to-water pump bolts to 10 N.m (89 lb in).
6. Remove the J 43651 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
7. Install the water pump access plate and bolts. Tighten: Tighten the water pump access bolts-to-front cover to 10 N.m (89 lb in).
8. Install a new O-ring seal on the water feed pipe.
9. Install the thermostat housing to block seal onto the thermostat housing, if damaged.
10. Install the water feed pipe into the water pump assembly.
11. Align the water feed pipe to the thermostat housing assembly.
12. Seat the water feed O-ring seal by pushing and twisting toward the water pump. Take care not to tear or damage the O-ring.
13. The water feed pipe has a locating tab to assure proper alignment.
14. Position the thermostat housing against the engine. Be sure that the thermostat housing pipe is properly positioned against the support bracket near the front of the engine.
15. Install the thermostat housing to block bolts. Tighten: Tighten the thermostat housing-to-block bolts to 10 N.m (89 lb in).
16. Connect the electrical connector to coolant temperature sensor.
17. Install the right hand inner splash shield and push pins.
18. Install the right hand tire assembly and wheel nuts. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).
19. Lower the vehicle.
20. Install the thermostat pipe bracket to cylinder head bolt. Tighten: Tighten the thermostat pipe bracket-to-cylinder head bolt to 8 N.m (71 lb in).
21. Install the exhaust manifold heat shield.
22. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 23 N.m (17 lb ft).
23. Verify the drain valves at the radiator and water pump are closed.
24. Fill the engine coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
25. Verify the repair and inspect for any leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Loosen the water pump pulley bolts.
3. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L.
4. Remove the water pump pulley bolts and pulley.
5. Remove the water pump bolts, pump, and gasket.
6. Clean the water pump mating surfaces.

1. Install the water pump gasket and pump (1).
2. Install the water pump bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the water pump pulley and bolt until snug.
4. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L.
5. Tighten the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
7. Inspect for leaks.

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 7

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
4. Loop a rope around each of the 2 tabs of the condenser and tie the rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.
6. Remove the upper radiator support brackets.
7. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
8. Remove the radiator outlet hose from the radiator.
9. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
10. Remove the radiator inlet hose from the radiator.
11. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
12. Remove the lower radiator air deflector retainers.
13. Remove the lower radiator air deflector.
14. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
15. Remove the right radiator air deflector retainers.
16. Remove the right radiator air deflector.
17. Remove the left radiator air deflector retainers.
18. Remove the left radiator air deflector.
19. Place a drain pan under the transmission oil cooler pipes.
20. Remove the transmission oil cooler pipes attachment nut from the transmission.
21. Remove the transmission oil cooler pipes from the transmission.
22. Remove the lower radiator support bracket bolts.
23. Remove the lower radiator support brackets.
24. Remove the radiator lower mounts.
25. Remove and discard the condenser mounting bolts.
26. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
27. Remove and discard the condenser mounting nuts from the radiator.
28. Remove the radiator air side seals.
29. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
30. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
31. Pry upward on the fan shroud tabs at the radiator clips.
32. Remove the cooling fan and shroud assembly from the radiator.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Install the cooling fan and shroud assembly to the radiator.
2. Snap the fan shroud tabs into the radiator clips.
3. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
6. Install the condenser mounting nuts to the radiator.
7. Insert the condenser mounting tabs into the radiator clips.
8. Install the condenser mounting bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
10. The radiator air side seals must be in the proper position for proper air flow.
11. Install the radiator lower mounts.
12. Install the lower radiator support brackets.
13. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
14. Install the transmission oil cooler pipes to the transmission.
15. Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
16. Install the left radiator air deflector.
17. Install the left radiator air deflector retainers.
18. Install the right radiator air deflector.
19. Install the right radiator air deflector retainers.
20. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
21. Install the lower radiator air deflector.
22. Install the lower radiator air deflector retainers.
23. Lower the vehicle.
24. Install the radiator inlet hose to the radiator.
25. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
26. Install the radiator outlet hose to the radiator.
27. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
28. Remove the rope attached to the condenser and upper tie bar.
29. Install the upper radiator support brackets.
30. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (7 lb ft).
31. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
32. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
33. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
34. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) in Automatic Transaxle - 4T40-E/4T45-E.

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 12

Scheme 13

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
4. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.
6. Remove the upper radiator support brackets.
7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
8. Remove the surge tank outlet hose from the radiator.
9. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
10. Remove the radiator inlet hose from the radiator.
11. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
12. Remove the lower radiator air deflector retainers.
13. Remove the lower radiator air deflector.
14. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
15. Remove the right radiator air deflector retainers.
16. Remove the right radiator air deflector.
17. Remove the left radiator air deflector retainers.
18. Remove the left radiator air deflector.
19. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
20. Remove the radiator outlet hose from the radiator.
21. Place a drain pan under the transmission oil cooler pipes.
22. Remove the transmission oil cooler pipe attachment nut from the transmission.
23. Remove the transmission oil cooler pipes from the transmission.
24. Remove the lower radiator support bracket bolts.
25. Remove the lower radiator support brackets.
26. Remove the radiator lower mounts.
27. Remove and discard the condenser mounting bolts from the radiator.
28. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
29. Remove and discard the condenser mounting nuts from the radiator.
30. Remove the radiator air side seals.
31. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
32. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
33. Pry upward on the fan shroud tabs at the radiator clips.
34. Remove the cooling fan and shroud assembly.

1. Install the cooling fan and shroud assembly to the radiator.
2. Snap the fan shroud tabs into the radiator clips.
3. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
6. Install the condenser mounting nuts to the radiator.
7. Insert the condenser mounting tabs into the radiator clips.
8. Install the condenser to the radiator bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
10. The radiator air side seals must be in the proper position for proper air flow.
11. Install the radiator lower mounts.
12. Install the lower radiator support brackets.
13. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
14. Install the transmission oil cooler pipes to the transmission.
15. Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
16. Install the radiator outlet hose to the radiator.
17. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
18. Install the left radiator air deflector.
19. Install the left radiator air deflector retainers.
20. Install the right radiator air deflector.
21. Install the right radiator air deflector retainers.
22. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
23. Install the lower radiator air deflector.
24. Install the lower radiator air deflector retainers.
25. Lower the vehicle.
26. Install the radiator inlet hose to the radiator.
27. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
28. Install the surge tank outlet hose to the radiator.
29. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
30. Remove the rope attached to the condenser and upper tie bar.
31. Install the upper radiator support brackets.
32. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (7 lb ft).
33. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
34. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
35. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
36. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) in Automatic Transaxle - 4T40-E/4T45-E.

1. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
2. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Loop a rope around each of the two tabs of the condenser and tie the rope around the upper tie bar.
4. Remove the upper radiator support bracket bolts.
5. Remove the upper radiator support brackets.
6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
7. Remove the lower radiator air deflector retainers.
8. Remove the lower radiator air deflector.
9. Remove the lower radiator support bracket bolts.
10. Remove the lower radiator support brackets.
11. Remove the radiator lower mounts.

1. Install the radiator lower mounts.
2. Install the lower radiator support brackets.
3. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
4. Install the lower radiator air deflector.
5. Install the lower radiator air deflector retainers.
6. Lower the vehicle.
7. Remove the rope attached to the condenser and upper tie bar.
8. Install the upper radiator support brackets.
9. Install the upper radiator bracket bolts. Tighten: Tighten the bolts to 10 N.m (7 lb ft).
10. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
11. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.

Scheme 14

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the lower radiator air deflector retainers.
3. Remove the lower radiator air deflector.

1. Install the lower radiator air deflector.
2. Install the lower radiator air deflector retainers.
3. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the left side radiator air deflector retainers.
3. Remove the left side radiator air deflector.
4. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
5. Remove the right side radiator air deflector retainers.
6. Remove the right side radiator air deflector.

1. Install the right side radiator air deflector.
2. Install the right side radiator air deflector retainers.
3. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Install the left side radiator air deflector.
5. Install the left side radiator air deflector retainers.
6. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the left side radiator air deflector retainers.
3. Remove the left side radiator air deflector.
4. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
5. Remove the right side radiator air deflector retainers.
6. Remove the right side radiator air deflector.

1. Install the right side radiator air deflector.
2. Install the right side radiator air deflector retainers.
3. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Install the left side radiator air deflector.
5. Install the left side radiator air deflector retainers.
6. Lower the vehicle.

1. Remove the front bumper upper fascia support. Refer to «Fascia Support Replacement - Front Bumper Upper»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#bumper-system) in Bumpers.
2. Remove the upper radiator air deflector retainers.
3. Remove the wire harness clips at the bumper beam.
4. Remove the upper radiator air deflector.

1. Install the upper radiator air deflector.
2. Install the wire harness clips at the bumper beam.
3. Install the upper radiator air deflector retainers.
4. Install the front bumper upper fascia support. Refer to «Fascia Support Replacement - Front Bumper Upper»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#bumper-system) in Bumpers.

1. Disconnect the coolant heater core (1).
2. Remove the coolant heater bolt.
3. 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 core (1).

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Disconnect the engine coolant heater core from the engine coolant heater.
4. Loosen the engine coolant heater bolt. Do not remove the engine coolant heater bolt.
5. Remove the engine coolant heater.
6. Clean the engine coolant heater opening.

1. Coat the following components with the lubricant GM P/N 12345996 (Canadian P/N 10953501) or the equivalent: The engine block heater seal The cleaned surface of the engine block heater hole
2. Install the engine coolant heater. Position the engine coolant heater element at the 3 o'clock position (2), as shown. Final installed position between 2 o'clock (1) and 4 o'clock (3) is acceptable.
3. Tighten the engine coolant heater bolt. Tighten: Tighten the bolt to 2 N.m (18 lb in).
4. The engine coolant heater core must not touch the engine, hot pipes, manifold, or any moving parts. Secure the engine coolant heater core with tie straps as required.
5. Connect the engine coolant heater core to the engine coolant heater.
6. Lower the vehicle.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) .
8. Inspect for leaks.

1. Disconnect the engine coolant heater core (1).
2. Remove the clips from the engine mount and surge tank.

1. Install the clips from the engine mount and surge tank.
2. Connect the engine coolant heater core (1).

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Disconnect the engine coolant heater core from the engine coolant heater.
3. Remove the engine coolant heater core straps.
4. Disconnect the upper engine coolant heater core from the diagonal brace strap.
5. Remove the engine coolant heater core.

1. Install the engine coolant heater core.
2. Connect the engine coolant heater core to the engine coolant heater.
3. Lower the vehicle.
4. Route the engine coolant heater core to the air cleaner housing.
5. Install the new engine coolant heater core straps.

Cooling Fan Control

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a series/parallel configuration that allows the powertrain control module (PCM) to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood fuse block. The ground path is provided at G106.

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

During high speed operation the PCM supplies the ground path for the cooling fan 1 relay through the low speed cooling fan relay control circuit. After a 3 second delay, the PCM supplies a ground path for the cooling fan 2 relay and the cooling fan S/P relay through the high speed cooling fan relay control circuit. This energizes the cooling fan 2 relay coil, closes the relay contacts, and provides a ground path for the left cooling fan. At the same time the cooling fan S/P relay coil is energized closing the relay contacts and provides battery positive voltage from the cool 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.

The PCM commands Low Speed Fans on under the following conditions

1. Engine coolant temperature exceeds approximately 106°C (223°F).
2. When A/C is requested and the ambient temperature is more than 50°C (122°F).
3. A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
4. After the vehicle is shut off if the engine coolant temperature at key-off is more than 140°C (284°F) and system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.

The PCM commands High Speed Fans on under the following conditions

1. Engine coolant temperature reaches 110°C (230°F).
2. A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
3. When certain DTCs set

Engine Coolant Indicators

TEMP

1. The instrument panel cluster (IPC) illuminates the TEMP indicator when the powertrain control module (PCM) determines that the coolant temperature is more than 128°C (262°F). The IPC receives a discrete input from the PCM requesting illumination.
2. The IPC performs the display test at the start of each ignition cycle. The IPC illuminates the TEMP indicator.

Coolant Level Control

The engine cooling system contains an engine coolant level switch to alert the driver in the event of a low coolant level. When the engine coolant level in the coolant recovery reservoir falls below a certain level, the coolant level switch opens. When the IBCM detects an open or a high voltage level on the coolant level indicator control circuit, for at least 10 seconds, it will send a GM LAN message to the driver information center (DIC) requesting display of the low coolant level message. There is approximately a 10 second delay before the IBCM sends the GM LAN message to prevent the message from being displayed, due to coolant sloshing in the surge tank.

Coolant Heater

The optional engine coolant heater (RPO K05) operates using AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather -29°C (-20°F). The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug when not in use.

The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly.

Cooling Cycle

Coolant flows from the radiator outlet and into the water pump inlet. Some coolant flows from the water pump, to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost capability as the coolant warms up.

Coolant also flows from the water pump outlet and into the engine block. In the engine block, the coolant circulates through the water jackets surrounding the cylinders where the coolant absorbs heat.

The coolant then flows through the cylinder head gasket openings and into the cylinder heads. In the cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where the coolant absorbs additional heat.

From the cylinder heads, the coolant flows to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine reaches normal operating temperature, or the coolant will flow through the thermostat and into the radiator where the coolant is cooled. At this point, the coolant flow cycle is completed.

Efficient operation of the cooling system requires proper functioning of all cooling system components. The cooling system consists of the following components.

Coolant

The engine coolant is a solution made up of a 50/50 mixture of DEX-COOL and suitable drinking water. The coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the atmosphere.

Radiator

The radiator is a heat exchanger consisting of a core and 2 tanks. The aluminum core is a tube and fin crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere.

The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core.

The radiator also has a drain cock located in the bottom of the end tank. The drain cock unit includes the drain cock and drain cock seal.

Heat is removed from the coolant as the coolant passes through the radiator. The fins on the core transfer heat from the coolant passing through the tubes. Air passing between the fins absorbs the heat and cools the coolant.

Pressure Cap

The pressure cap seals and pressurizes the cooling system. The cap contains a blow off, or pressure valve and a vacuum, or an atmospheric valve

1. The pressure valve is held against the seat by a spring that protects the radiator by relieving pressure that exceeds 15 psi.
2. The vacuum valve is held against the seat by a spring that permits opening of the valve to relieve vacuum created when the cooling system cools. The vacuum, if not relieved, might cause the radiator to collapse.

The pressure cap allows the cooling system pressure to build up when the temperature increases. As the pressure builds, the boiling point of the coolant increases. Therefore, the engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant becomes, the faster the heat transfers from the radiator into the cooler air.

The pressure in the cooling system can get too high. When the pressure exceeds the strength of the spring, the pressure valve rises, venting the excess pressure.

As the engine cools, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open. This equalizes the pressure in the cooling system with the atmospheric pressure, preventing the radiator from collapsing.

Coolant Recovery System

The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The recovery reservoir is also called a recovery tank or expansion tank. This tank is partially filled with coolant and is connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator and the reservoir.

Air Baffles and Seals

The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent recirculation of hot air for better hot weather cooling and A/C condenser performance.

Water Pump

The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is a flat plate mounted on the pump shaft with a series of flat or curved blades or vanes. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force. The impeller shaft is supported by one or more sealed bearings, which never need to be lubricated. With a sealed bearing, grease cannot leak out, and dirt and water cannot get in.

The water pump circulates coolant throughout the cooling system. The pump is driven by the crankshaft from the drive belt.

Thermostat

The thermostat is a coolant flow control component, whose purpose is to regulate the operating temperature of the engine. The thermostat utilizes a temperature sensitive wax-pellet element, which connects to a valve through a piston. Heating causing the element to expand and exert pressure against a rubber diaphragm. This pressure forces the valve to open. Cooling causes the element to contract. This contraction allows a spring to push the valve closed.

When the coolant temperature is below 91°C (195°F), the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up quickly. After the coolant temperature reaches 91°C (195°F), the thermostat valve will open. The coolant is then allowed to circulate through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system, even after opening. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.

Transmission Oil Cooler

The transmission oil cooler is a heat exchanger and is located inside the end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant that surrounds the oil cooler as the transmission fluid passes through the cooler.

The transmission oil pump circulates the fluid through the feed line to the oil cooler. The fluid then flows through the cooler while the engine coolant absorbs heat from the fluid. The fluid is then pumped through the return line to the transmission.

Special Tools

Special Tools Illustration Tool Number/ Description J 24460-01 Radiator Pressure Tester J 24731 Tempil Stick J 26568 Coolant and Battery Fluid Tester J 38185 Hose Clamp Pliers J 42401 Radiator Cap/Surge Tank Tester Adapter J 43651 Water Pump Holding Tool

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

See also:
• Diagnostic System Check - Vehicle
• DTC Symptom Description
• Testing for Intermittent Conditions and Poor Connections
• Wiring Repairs
• Connector Repairs
• Powertrain Control Module (PCM) Replacement
• Checking Aftermarket Accessories
• Instrument Panel Cluster (IPC) Replacement
• Testing for Electrical Intermittents
• Circuit Testing
• Body Control Module (BCM) Programming/RPO Configuration
• Body Control Module Replacement
• HVAC Schematics
• HVAC Schematics
• Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
• Engine Coolant Temperature (ECT) Sensor Replacement
• Engine Coolant/Water in Transmission
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Lower Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Lifting and Jacking the Vehicle
• Water Pump Installation
• Capacities - Approximate Fluid
• Engine Block Assemble
• Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement
• Front Fender Liner Replacement
• Fastener Notice
• Transmission Fluid Cooler Line Quick Connect Fitting
• Transmission Fluid Checking Procedure
• Fascia Support Replacement - Front Bumper Upper
• Engine Cooling Schematics
• Cooling System Connector End Views
• Engine Overheating
• Symptoms - Engine Cooling
• Engine Coolant Temperature Indicator Always On
• Low Engine Coolant Indicator Always On
• Cooling Fan Always On
• Cooling Fan Inoperative (LX9)
• Cooling Fan Inoperative (L61)
• Loss of Coolant
• Coolant Heater Inoperative
• Engine Fails To Reach Normal Operating Temperature
• Flushing (L61)
• Flushing (LX9)
• Cooling System Leak Testing
• Pressure Cap Testing