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Engine Cooling System: Removal & Installation Chevrolet Malibu VIII рестайлинг

Cooling System (Mechanical) 42 illustrations ~3547 words

Radiator Surge Tank Replacement (LUK)

CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) Remove the radiator surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose Replacement (LUK) . Remove the radiator surge tank outlet hose. Refer to Radiator Surge Tank Outlet Hose Replacement (LUK)
1Radiator Surge Tank Retainer
2Radiator Surge Tank Procedure Slide the surge tank forward towards the front of the car to remove from brackets.

Radiator Surge Tank Replacement (LUK)

Scheme 1

Scheme 1: Radiator Surge Tank Replacement (LTG)
Scheme 1: Radiator Surge Tank Replacement (LTG)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
1Radiator Surge Tank Hose Clamps (Qty: 2) Procedure Reposition the radiator surge tank hose clamps using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers
2Radiator Surge Tank Inlet Hose
3Radiator Surge Tank Outlet Hose
4Radiator Surge Tank Bracket Clip Procedure Lift the surge tank clip from the radiator surge tank and bracket.
5Radiator Surge Tank Procedure Slide the radiator surge tank forward and lift out of the radiator surge tank bracket. After installation, fill the coolant reservoir to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) Inspect cooling system for leaks.

Radiator Surge Tank Replacement (LTG)

Scheme 2

Scheme 2: Radiator Surge Tank Inlet Hose Replacement (LKW)
Scheme 2: Radiator Surge Tank Inlet Hose Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LKW) . Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement (LKW) .
1Radiator Surge Tank Inlet Hose Clamp (Qty: 2) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Surge Tank Inlet Hose

Radiator Surge Tank Inlet Hose Replacement (LKW)

Scheme 3

Scheme 3: Radiator Surge Tank Inlet Hose Replacement (LUK)
Scheme 3: Radiator Surge Tank Inlet Hose Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Radiator Surge Tank Inlet Hose Clamp (Qty: 2) Procedure Disengage tension on the radiator surge tank inlet hose clamps using BO-38185 pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Surge Tank Inlet Hose Procedure Disconnect the retaining clip holding the radiator surge tank inlet hose to the high pressure fuel pump bracket.

Radiator Surge Tank Inlet Hose Replacement (LUK)

Scheme 4

Scheme 4: Radiator Surge Tank Inlet Hose Replacement (LTG)
Scheme 4: Radiator Surge Tank Inlet Hose Replacement (LTG)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LTG) .
1Radiator Surge Tank Inlet Hose Clamp (Qty: 2) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Surge Tank Inlet Hose Procedure Remove the radiator surge tank inlet hose retaining clips from the fuel feed front pipe. After installation, fill the coolant reservoir to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) Inspect cooling system for leaks.

Radiator Surge Tank Inlet Hose Replacement (LTG)

Scheme 5

Scheme 5: Radiator Surge Tank Outlet Hose Replacement (LUK)
Scheme 5: Radiator Surge Tank Outlet Hose Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
1Radiator Surge Tank Outlet Hose Clamp (Qty: 3)
2Radiator Surge Tank Outlet Hose

Radiator Surge Tank Outlet Hose Replacement (LUK)

Scheme 6

Scheme 6: Radiator Inlet Hose Replacement (LKW)
Scheme 6: Radiator Inlet Hose Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LKW) . Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
1Radiator Inlet Hose Clamp (Qty: 2) Procedure Reposition the radiator inlet hose clamps using the BO-38185 hose clamp pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Inlet Hose Procedure Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Inspect the cooling system for leaks.

Radiator Inlet Hose Replacement (LKW)

Scheme 7

Scheme 7: Radiator Inlet Hose Replacement (LUK)
Scheme 7: Radiator Inlet Hose Replacement (LUK)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
1Radiator Inlet Hose Clamps (Qty: 2)
2Radiator Inlet Hose Support Bracket Fastener CAUTION: Refer to Fastener Caution . Tighten: 25 (18 lb ft)
3Radiator Inlet Hose
CAUTION
Refer to Fastener Caution .

Radiator Inlet Hose Replacement (LUK)

Scheme 8

Scheme 8: Radiator Inlet Hose Replacement (LTG)
Scheme 8: Radiator Inlet Hose Replacement (LTG)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
1Radiator Inlet Hose Clamp (Qty: 2) Procedure Reposition the radiator inlet hose clamps using the BO-38185 hose clamp pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Inlet Hose Procedure Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Inspect the cooling system for leaks.

Radiator Inlet Hose Replacement (LTG)

Scheme 9

Scheme 9: Radiator Outlet Hose Replacement (LKW)
Scheme 9: Radiator Outlet Hose Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LKW) .
1Radiator Outlet Hose Clamp (Qty: 2) Procedure Reposition the radiator outlet hose clamps using the BO-38185 hose clamp pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Outlet Hose Procedure Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Inspect the cooling system for leaks.

Radiator Outlet Hose Replacement (LKW)

Scheme 10

Scheme 10: Radiator Outlet Hose Replacement (LUK)
Scheme 10: Radiator Outlet Hose Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Reposition the engine control module out of the way. Refer to Engine Control Module Replacement . Reposition the drive motor battery coolant air separator out of the way. Refer to Drive Motor Battery Coolant/Air Separator Replacement .
1Radiator Outlet Hose Clamps
2Radiator Outlet Hose

Radiator Outlet Hose Replacement (LUK)

Scheme 11

Scheme 11: Radiator Outlet Hose Replacement (LTG)
Scheme 11: Radiator Outlet Hose Replacement (LTG)
CalloutComponent Name
Preliminary Procedure Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (LTG) . Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
1Radiator Outlet Hose Clamp (Qty: 2) Procedure Reposition the radiator outlet hose clamps using the BO-38185 hose clamp pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Outlet Hose Procedure Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Inspect the cooling system for leaks. Refer to Cooling System Leak Testing .

Radiator Outlet Hose Replacement (LTG)

Engine Coolant Fan Replacement (LTG)

CalloutComponent Name
Preliminary Procedure Remove the engine coolant fan shroud from the vehicle. Refer to Engine Coolant Fan Shroud Replacement (LTG) .
1Engine Coolant Fan Fastener (Qty: 6) (Qty: 3 Per Fan Assembly) CAUTION: Refer to Fastener Caution .
2Engine Fan Shroud
3Engine Coolant Fan Retainer (Qty: 2)
4Engine Coolant Fan (Qty: 2)
5Engine Coolant Fan Motor (Qty: 2)
CAUTION
Refer to Fastener Caution .

Engine Coolant Fan Replacement (LTG)

Scheme 12

Scheme 12: Turbocharger Coolant Feed Pipe Replacement
Scheme 12: Turbocharger Coolant Feed Pipe Replacement
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the catalytic converter. Refer to Catalytic Converter Replacement (LUK) , Catalytic Converter Replacement (LTG) , Catalytic Converter Replacement (LKW) . Remove the engine mount bracket heat shield. NOTE: Replace hose clamp if necessary. Special Tools BO-38185 Hose Clamp PliersFor equivalent regional tools, refer to Special Tools .
1Turbocharger Coolant Feed Pipe Bolt Tighten 35 (26 lb ft)
2Turbocharger Coolant Feed Pipe Washer (Qty: 2) NOTE: Install 2 NEW washers.
3Turbocharger Coolant Feed Pipe Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 10 (89 lb in)
4Gasket
5Hose Clamp
6Turbocharger Coolant Feed Pipe
NOTE
Replace hose clamp if necessary.
NOTE
Install 2 NEW washers.
CAUTION
Refer to Fastener Caution .

Turbocharger Coolant Feed Pipe Replacement

Scheme 13

Scheme 13: Turbocharger Coolant Return Pipe Replacement
Scheme 13: Turbocharger Coolant Return Pipe Replacement
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LTG) , Intake Manifold Cover Replacement (LKW) . Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement . NOTE: Replace hose clamp if necessary. Special Tools BO-38185 Hose Clamp PliersFor equivalent regional tools, refer to Special Tools .
1Engine Coolant Air Bleed Hose
2Turbocharger Coolant Return Pipe Fastener CAUTION: Refer to Fastener Caution . Tighten: 10 (89 lb in)
3Turbocharger Coolant Return Pipe Bolt Tighten 35 N.m (26 lb ft)
4Turbocharger Coolant Return Pipe Washer (Qty: 2) NOTE: Install 2 NEW washers.
5Turbocharger Coolant Return Pipe
NOTE
Replace hose clamp if necessary.
CAUTION
Refer to Fastener Caution .
NOTE
Install 2 NEW washers.

Turbocharger Coolant Return Pipe Replacement

Removal Procedure

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement (LTG)»(ref-609211-S20609784982014041500000) .
  3. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-609150-S37775200012014041500000) .
  4. Remove the radiator inlet hose (1) from the water outlet (2).
  5. Remove the thermostat bypass hose (2) from the thermostat bypass pipe (1) and the water outlet (3).

Installation Procedure

  1. Install the thermostat bypass hose (2) to the thermostat bypass pipe (1) and the water outlet (3).
  2. Install the radiator inlet hose (1) to the water outlet (2).
  3. Install the battery tray. Refer to «Battery Tray Replacement»(ref-609150-S37775200012014041500000) .
  4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement (LTG)»(ref-609211-S20609784982014041500000) .
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  6. Start the engine and check for coolant leaks.
  1. Remove the thermostat bypass pipe. Refer to «Thermostat Bypass Pipe Replacement (LKW)»(ref-609148-S26257037802014041500000) .
  2. Remove the thermostat bypass hose (2) from the thermostat bypass pipe (1) and the water outlet (3).
  1. Install the thermostat bypass hose (2) to the thermostat bypass pipe (1) and the water outlet (3).
  2. Install the thermostat bypass pipe. Refer to «Thermostat Bypass Pipe Replacement (LKW)»(ref-609148-S26257037802014041500000) .

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

Note. The thermostat and thermostat housing are serviced as an assembly.

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LTG)»(ref-609155-S08955059212014041500000) .
  3. Remove the radiator outlet hose (1) from the engine coolant thermostat housing (2).
  4. Remove the engine coolant thermostat housing fasteners (3) and remove the engine coolant thermostat housing (2).
  5. Discard the engine coolant thermostat housing seal (1).
  1. Clean the sealing surfaces.
  2. Install the engine coolant thermostat housing (2) with a NEW seal (1) and tighten the fasteners (3) to 10 (89 lb in).
  3. Install the radiator outlet hose (1) to the engine coolant thermostat housing (2).
  4. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LTG)»(ref-609155-S08955059212014041500000) .
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  6. Start the engine and check for coolant leaks.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-609111-S25517100942014041500000) .
  2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  3. Remove the Engine Control Module (ECM). Refer to «Engine Control Module Replacement»(ref-609170-S38925392082014041500000) . NOTE: Do not disconnect electrical connectors from the ECM.
  4. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUK)»(ref-609155-S16237462922014041500000) .
  5. Remove the following hoses from the thermostat housing (6) : Radiator Outlet Hose (1). Surge Tank Hose (2). Heater Coolant Pump Hose (3). Heater Inlet Hose (4).
  6. Disconnect the Engine Coolant Temperature (ECT) sensor (1).
  7. Remove the thermostat housing fasteners (1) .
  8. Remove the thermostat housing (2) from the vehicle.
  9. Remove the water transfer pipe (5) from the thermostat housing, if necessary.
  10. Remove and discard the water transfer pipe O-ring seals (4) and the thermostat housing seal (3).
  11. Remove the thermostat cover fasteners (1) and cover (2), if necessary.
  12. Remove the thermostat (3), if necessary.
  13. Remove and discard the thermostat cover O-ring seal, if necessary.
  14. Remove all debris and thread sealant from the engine coolant temperature (ECT) sensor and bolt holes if the housing is being re-used.
  1. If installing a NEW thermostat housing transfer the thermostat ,water inlet and the ECT sensor.
  2. Install a NEW thermostat cover O-ring seal into the recess groove.
  3. Install the thermostat (3), if necessary.
  4. Install the thermostat cover fasteners (1), if necessary and tighten to 10 N.m (89 lb in).
  5. Install a NEW thermostat housing to engine gasket onto the thermostat housing.
  6. Load the thermostat housing assembly into position.
  7. Install NEW O-ring seals (4) onto the water feed pipe (5).
  8. Install the water feed pipe (5) into the thermostat housing aligning locator tab.
  9. Align the water pipe (5) to water pump.
  10. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  11. Position the thermostat housing (2) against the engine with a NEW seal (3).
  12. Install the thermostat housing fasteners (1) and tighten to 10 N.m (89 lb in).
  13. Install the ECT sensor, if necessary and tighten to 20 N.m (15 lb ft).
  14. Install the following hoses from the thermostat housing (6) : Radiator Outlet Hose (1). Surge Tank Hose (2). Heater Coolant Pump Hose (3). Heater Inlet Hose (4).
  15. Connect the ECT sensor (1).
  16. Verify the drain valves at the radiator and water pump are closed.
  17. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUK)»(ref-609155-S16237462922014041500000) .
  18. Install the ECM. Refer to «Engine Control Module Replacement»(ref-609170-S38925392082014041500000) .
  19. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LKW)»(ref-609155-S30729556762014041500000) .
  3. Remove the radiator outlet hose (1) from the engine coolant thermostat housing (2).
  4. If equipped, disconnect the connector (3) from the engine coolant thermostat housing (2).
  5. Remove the engine coolant thermostat housing fasteners (3) and remove the engine coolant thermostat housing (2).
  6. Discard the engine coolant thermostat housing seal (1).
  1. Clean the sealing surfaces.
  2. Install the engine coolant thermostat housing (2) with a NEW seal (1) and the fasteners (3).
  3. Tighten the fasteners (3) to 10 (89 lb in).
  4. If equipped, connect the connector (3) to the engine coolant thermostat housing (2).
  5. Install the radiator outlet hose (1) to the engine coolant thermostat housing (2).
  6. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LKW)»(ref-609155-S30729556762014041500000) .
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  8. Start the engine and check for coolant leaks.

Scheme 14

Scheme 14: Engine Coolant Thermostat Replacement (LUK)
Scheme 14: Engine Coolant Thermostat Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Draining the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . NOTE: Do not disconnect electrical connectors from the ECM. Remove the Engine Control Module (ECM). Refer to Engine Control Module Replacement . Disconnect the radiator outlet hose from the water inlet housing. Disconnect the radiator surge tank hose from the water inlet housing. Refer to Radiator Surge Tank Outlet Hose Replacement (LUK) .
1Engine Coolant Thermostat Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 10 N.m (88 lb in)
2Engine Coolant Thermostat
NOTE
Do not disconnect electrical connectors from the ECM.
CAUTION
Refer to Fastener Caution .

Engine Coolant Thermostat Replacement (LUK)

Scheme 15

Scheme 15: Engine Coolant Air Bleed Pipe Replacement (LTG)
Scheme 15: Engine Coolant Air Bleed Pipe Replacement (LTG)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LTG) . Remove the positive crankcase ventilation hose/pipe/tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Camshaft Cover to Air Cleaner Resonator to Outlet Duct) . Disconnect the electrical wiring harness connector from the ignition coil. NOTE: Replace hose clamps if necessary. Special Tools BO-38185 Hose Clamp PliersFor equivalent regional tools, refer to Special Tools .
1Surge Tank Vent Hose Clamp
2Engine Coolant Air Bleed Hose Clamp
3Engine Coolant Air Bleed Pipe Fastener CAUTION: Refer to Fastener Caution . Tighten: 10 (89 lb in)
4Engine Coolant Air Bleed Pipe
5Seal NOTE: Install NEW seal
NOTE
Replace hose clamps if necessary.
CAUTION
Refer to Fastener Caution .
NOTE
Install NEW seal

Engine Coolant Air Bleed Pipe Replacement (LTG)

Scheme 16

Scheme 16: Engine Coolant Air Bleed Pipe Replacement (LKW)
Scheme 16: Engine Coolant Air Bleed Pipe Replacement (LKW)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LKW) .
1Radiator Surge Tank Inlet Hose Procedure Reposition the radiator surge tank hose using the BO-38185 Hose Clamp Pliers NOTE: Repalce hose clamp if necessary Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Engine Coolant Air Bleed Pipe Fastener CAUTION: Refer to Fastener Caution . Tighten: 10 (89 lb in)
3Engine Coolant Air Bleed Pipe
NOTE
Repalce hose clamp if necessary
CAUTION
Refer to Fastener Caution .

Engine Coolant Air Bleed Pipe Replacement (LKW)

Scheme 17

Scheme 17: Engine Coolant Air Bleed Hose Replacement (LTG)
Scheme 17: Engine Coolant Air Bleed Hose Replacement (LTG)
CalloutComponent Name
Preliminary Procedure Remove the engine coolant air bleed pipe. Refer to Engine Coolant Air Bleed Pipe Replacement (LTG) . Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
1Engine Coolant Air Bleed Hose NOTE: Replace hose clamps if necessary.
NOTE
Replace hose clamps if necessary.

Engine Coolant Air Bleed Hose Replacement (LTG)

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement (LKW)»(ref-609211-S39936756832014041500000) .
  3. Reposition the engine control module and bracket without disconnecting the module electrical connectors. Refer to «Engine Control Module Replacement (LKW)»(ref-609171-S20550585252014041500000) .
  4. Disconnect the engine coolant temperature (ECT) sensor connector (3) from the water outlet (2).
  5. Remove the following hoses from the water outlet: Radiator inlet hose (1). Heater inlet hose (4). Heater outlet hose (5).
  6. If equipped, remove the secondary air injection inlet hose. Refer to «Secondary Air Injection Pump Inlet Hose Replacement (LKW)»(ref-609171-S10293246292014041500000) .
  7. Remove the water outlet fasteners (3) and remove the water outlet (2).
  8. Remove the thermostat bypass hose (2) from the water outlet (3).
  9. Discard the water outlet seal (1).
  1. Install the thermostat bypass hose (2) to the water outlet (3).
  2. Install the water outlet (2) into position with a NEW seal (1).
  3. Install the water outlet fasteners (3) and tighten to 12 (106 lb in).
  4. If equipped, install the secondary air injection inlet hose. Refer to «Secondary Air Injection Pump Inlet Hose Replacement (LKW)»(ref-609171-S10293246292014041500000) .
  5. Connect the engine coolant temperature (ECT) sensor connector (3) to the water outlet (2).
  6. Install the following hoses to the water outlet: Radiator inlet hose (1). Heater inlet hose (4). Heater outlet hose (5).
  7. Install the engine control module and bracket. Refer to «Engine Control Module Replacement (LKW)»(ref-609171-S20550585252014041500000) .
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement (LKW)»(ref-609211-S39936756832014041500000) .
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  10. Start the engine and check for coolant leaks.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement (LTG)»(ref-609211-S20609784982014041500000) .
  3. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LTG)»(ref-609155-S08955059212014041500000) .
  4. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-609150-S37775200012014041500000) .
  5. Remove the radiator inlet hose (1) from the water outlet (2).
  6. Remove the thermostat bypass hose (2) from the thermostat bypass pipe (1).
  7. Remove the hose (1) from the thermostat bypass pipe (2).
  8. Remove the thermostat bypass pipe fasteners (1).
  9. Remove the thermostat bypass pipe (2) and discard the gasket (3).
  1. Install the thermostat bypass pipe (2) into position with a NEW gasket (3).
  2. Install the hose (1) on the thermostat bypass pipe (2).
  3. Install the thermostat bypass pipe fasteners (1) and tighten to 10 (89 lb in).
  4. Install the thermostat bypass hose (2) on the thermostat bypass pipe (1).
  5. Install the radiator inlet hose (1) to the water outlet (2).
  6. Install the battery tray. Refer to «Battery Tray Replacement»(ref-609150-S37775200012014041500000) .
  7. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LTG)»(ref-609155-S08955059212014041500000) .
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement (LTG)»(ref-609211-S20609784982014041500000) .
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  10. Start the engine and check for coolant leaks.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LKW)»(ref-609155-S30729556762014041500000) .
  3. Reposition the engine control module and bracket without disconnecting the module electrical connectors. Refer to «Engine Control Module Replacement (LKW)»(ref-609171-S20550585252014041500000) .
  4. If equipped, remove the secondary air injection inlet hose. Refer to «Secondary Air Injection Pump Inlet Hose Replacement (LKW)»(ref-609171-S10293246292014041500000) .
  5. Remove the radiator inlet hose (1) from the water outlet (2).
  6. Remove the thermostat bypass pipe fasteners (1).
  7. Remove the thermostat bypass hose (2) from the thermostat bypass pipe (1).
  8. Remove the thermostat bypass pipe (2) and discard the gasket (1).
  1. Install the thermostat bypass pipe (2) into position with a NEW gasket (1).
  2. Install the thermostat bypass pipe fasteners (3) and tighten to 10 (89 lb in).
  3. Install the thermostat bypass hose (2) to the thermostat bypass pipe (1).
  4. Install the radiator inlet hose (1) to the water outlet (2).
  5. If equipped, install the secondary air injection inlet hose. Refer to «Secondary Air Injection Pump Inlet Hose Replacement (LKW)»(ref-609171-S10293246292014041500000) .
  6. Install the engine control module and bracket. Refer to «Engine Control Module Replacement (LKW)»(ref-609171-S20550585252014041500000) .
  7. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LKW)»(ref-609155-S30729556762014041500000) .
  8. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  9. Start the engine and check for coolant leaks.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-609211-S37861301942014041500000) .
  3. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LTG)»(ref-609155-S08955059212014041500000) .
  4. Using the BO-38185 hose clamp pliers, remove the radiator outlet hose (1) from the water outlet (2).
  5. Remove the engine harness retainer (1) from the water pump (2) .
  6. Remove the thermostat bypass pipe fasteners (1) and remove the thermostat bypass pipe (2) from the water pump.
  7. Discard the thermostat bypass pipe gasket (3).
  8. Remove the water pump fasteners (1) and (2) remove the water pump (3).
  9. Discard the water pump seal (4).
  1. Install the water pump (3) into position with a NEW water pump seal (4) and hand tighten the bolts.
  2. Tighten (1) bolts to 25 (18 lb ft).
  3. Tighten (2) bolt to 25 (18 lb ft).
  4. Install the thermostat bypass pipe (2) to the water pump with a NEW gasket (3) and tighten the fasteners (1) to 10 (89 lb in).
  5. Install the engine wiring harness retainer (1) to the water pump (2).
  6. Using the BO-38185 hose clamp pliers, install the radiator outlet hose (1) to the water outlet (2).
  7. Install the drive belt. Refer to «Drive Belt Replacement»(ref-609211-S37861301942014041500000) .
  8. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LTG)»(ref-609155-S08955059212014041500000) .
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  10. Start the engine and check for coolant leaks.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-609170-S23166932872014041500000) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-609113-S39892321352014041500000) .
  3. Remove the right front wheelhouse front liner. Refer to «Front Wheelhouse Front Liner Replacement (Left Side)»(ref-609146-S14630192292014041500000) , «Front Wheelhouse Front Liner Replacement (Right Side)»(ref-609146-S05893536892014041500000) .
  4. Remove the engine coolant thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LUK)»(ref-609148-S06706011772014041500000) .
  5. If equipped, remove the coolant heater.
  6. Drain the coolant from the water pump using the plug at the bottom of the pump. Install the plug when finished.
  7. Remove the water pump cover (2), fasteners (3) and gasket (1) from the engine front cover.
  8. Align the EN-43651 water pump holding tool (1) with the threads on the water pump sprocket. Tighten the water pump holding tool fasteners (2).
  9. Secure the water pump holding tool with the previously removed water pump cover fasteners (1) into the engine front cover.
  10. Remove the water pump sprocket to water pump fasteners (1).
  11. Remove the front water pump fasteners (1).
  12. Remove the rear water pump fasteners (1).
  13. Remove the water pump (1).
  14. If replacing the water pump cover remove the water pump rear cover fasteners (4).
  15. Separate the water pump cover (1) from the water pump (3).
  16. Remove and discard the water pump O-ring seal (2).
  1. If replacing the water pump cover (1), install a new O-ring (2) to the water pump (3) and tighten the fasteners (4) to 25 N.m (18 lb ft).
  2. Using a guide pin (2), align the pin with the water pump holding tool.
  3. Position the water pump (1) against the engine block and hand tighten the water pump fasteners (3).
  4. Install 2 water pump sprocket to water pump fasteners (1). After the fasteners are snug, remove the guide pin (2) and install the 3rd fastener (3) and tighten to 10 N.m (89 lb in).
  5. Install the water pump fasteners (1) at the front of the engine. Hand tighten at this time.
  6. Tighten the water pump fasteners at the front and rear of the water pump to 25 N.m (18 lb ft).
  7. Remove the water pump cover fasteners (1) from the engine front cover and water pump holding tool.
  8. Remove the EN-43651 water pump holding tool (1) from the water pump sprocket.
  9. Install the water pump access plate (2) gasket (1) and fasteners (3) and tighten to 10 N.m (89 lb in).
  10. If equipped, Install the coolant heater.
  11. Install the engine coolant thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LUK)»(ref-609148-S06706011772014041500000) .
  12. Install the right front wheelhouse front liner. Refer to «Front Wheelhouse Front Liner Replacement (Left Side)»(ref-609146-S14630192292014041500000) , «Front Wheelhouse Front Liner Replacement (Right Side)»(ref-609146-S05893536892014041500000) .
  13. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUK)»(ref-609155-S16237462922014041500000) .
  14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-609113-S39892321352014041500000) .
  15. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-609170-S23166932872014041500000) .
  16. Refill the coolant system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-609211-S37861301942014041500000) .
  3. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LKW)»(ref-609155-S30729556762014041500000) .
  4. Remove the radiator outlet hose (1) from the water outlet (2).
  5. Disconnect the thermostat housing connector (1) and remove the engine harness retainer (2) from the water pump.
  6. Remove the thermostat bypass pipe fasteners (1) and remove the thermostat bypass pipe (2) from the water pump.
  7. Discard the thermostat bypass pipe gasket (3).
  8. Remove the water pump fasteners (3) and (4) remove the water pump (2).
  9. Discard the water pump seal (1).
  1. Install the water pump (2) into position with a NEW water pump seal (1) and hand tighten the bolts.
  2. Tighten (3) bolts to 25 (18 lb ft).
  3. Tighten (4) bolt to 25 (18 lb ft).
  4. Install the thermostat bypass pipe (2) to the water pump with a NEW gasket (3) and tighten the fasteners (1) to 10 (89 lb in).
  5. Connect the connector (1) to the water outlet.
  6. Install the engine wiring harness retainer (2) to the water pump.
  7. Install the radiator outlet hose (1) to the water outlet (2).
  8. Install the drive belt. Refer to «Drive Belt Replacement»(ref-609211-S37861301942014041500000) .
  9. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LKW)»(ref-609155-S30729556762014041500000) .
  10. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  11. Start the engine and check for coolant leaks.

Scheme 18

Scheme 18: Auxiliary Water Pump Replacement (LKW)
Scheme 18: Auxiliary Water Pump Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement (LKW) . Disconnect the auxiliary heater outlet hose from the retaining clip. Remove the heater outlet hose from the radiator surge tank. Refer to Heater Outlet Hose Replacement (Heater Core Outlet Tube to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Auxiliary Water Pump to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Radiator Surge Tank Auxiliary to Warer Pump to Water Outlet LKW) . Remove the heater outlet hose from the water outlet. Refer to Heater Outlet Hose Replacement (Heater Core Outlet Tube to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Auxiliary Water Pump to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Radiator Surge Tank Auxiliary to Warer Pump to Water Outlet LKW) . Remove the heater coolant pump hose from the heater outlet pipe. Refer to Heater Outlet Hose Replacement (Heater Core Outlet Tube to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Auxiliary Water Pump to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Radiator Surge Tank Auxiliary to Warer Pump to Water Outlet LKW) .
1Auxiliary Water Pump Bracket Bolt CAUTION: Refer to Fastener Caution . Tighten 10 (89 lb in)
2Auxiliary Water Pump Procedures Disconnect the auxiliary water pump electrical connector. If replacing the auxiliary water pump transfer the heater outlet hoses to the new auxiliary water pump. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Inspect the cooling system for leaks.
CAUTION
Refer to Fastener Caution .

Auxiliary Water Pump Replacement (LKW)

Scheme 19

Scheme 19: Auxiliary Water Pump Replacement (LUK)
Scheme 19: Auxiliary Water Pump Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove intake manifold cover. Refer to Intake Manifold Cover Replacement . Disconnect the auxiliary heater outlet hose from the clip bracket. Refer to Auxiliary Heater Outlet Hose Replacement (LUK) . Disconnect the heater coolant pump hose from the heater outlet hose connector. Refer to Heater Coolant Pump Hose Replacement .
1Auxiliary Water Pump Bracket Bolt CAUTION: Refer to Fastener Caution . Tighten 10 (89 lb in)
2Auxiliary Water Pump Assembly Procedures Disconnect the auxiliary water pump connector. Transfer the auxiliary heater outlet hose and heater coolant pump hose. Level the engine coolant to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Inspect for engine coolant leaks.
CAUTION
Refer to Fastener Caution .

Auxiliary Water Pump Replacement (LUK)

Scheme 20

Scheme 20: Engine Coolant Temperature Sensor Replacement - Radiator (LUK, LTG)
Scheme 20: Engine Coolant Temperature Sensor Replacement - Radiator (LUK, LTG)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front wheel house front liner. Refer to Front Wheelhouse Front Liner Replacement (Left Side) , Front Wheelhouse Front Liner Replacement (Right Side) .
1Engine Coolant Temperature Sensor Retainer
2Engine Coolant Temperature Sensor Procedure Disconnect the electrical connector. Fill the coolant system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .

Engine Coolant Temperature Sensor Replacement - Radiator (LUK LTG)

Scheme 21

Scheme 21: Radiator Drain Cock Replacement (LKW, LUK)
Scheme 21: Radiator Drain Cock Replacement (LKW, LUK)
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . To gain access to the drain cock reposition the right front wheelhouse liner. Place a drain pan under the right side of the radiator.
1Radiator Drain Cock Attach a drain hose to the radiator drain port to guide the coolant into the drain pan. Fill the coolant to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .

Radiator Drain Cock Replacement (LKW, LUK)

Scheme 22

Scheme 22: Radiator Drain Cock Replacement (LTG)
Scheme 22: Radiator Drain Cock Replacement (LTG)
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Place a drain pan under the right side of the radiator.
1Radiator Drain Cock NOTE: Attach a drain hose to the radiator drain port to guide the coolant into the drain pan. Procedure Fill the coolant to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) .
NOTE
Attach a drain hose to the radiator drain port to guide the coolant into the drain pan.

Radiator Drain Cock Replacement (LTG)

Scheme 23

Scheme 23: Engine Coolant Fan Shroud Replacement (LKW)
Scheme 23: Engine Coolant Fan Shroud Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LKW) . Remove the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement . Disconnect the engine coolant fan motor connectors. Remove the electrical wiring harness from the engine coolant fan shroud and reposition out of the way. Unclip the transmission fluid cooler pipes from the engine coolant fan shroud and reposition out of the way.
1Engine Coolant Fan Shroud Fastener (Qty: 2) CAUTION: Refer to Fastener Caution .
2Engine Coolant Fan Shroud Procedure Transfer all necessary parts.
CAUTION
Refer to Fastener Caution .

Engine Coolant Fan Shroud Replacement (LKW)

Scheme 24

Scheme 24: Engine Coolant Fan Shroud Replacement (LTG)
Scheme 24: Engine Coolant Fan Shroud Replacement (LTG)
CalloutComponent Name
Preliminary Procedures Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement (LTG) . Disconnect the engine coolant fan motor electrical connectors. Unclip the wiring harness from the shroud. Release the transmission lines from the fan shroud retainers.
1Engine Coolant Fan Shroud Bolt (Qty: 2) CAUTION: Refer to Fastener Caution .
2Engine Coolant Fan Shroud Procedure Tilt the engine coolant fan shroud towards the engine and lift it off the radiator.
CAUTION
Refer to Fastener Caution .

Engine Coolant Fan Shroud Replacement (LTG)

Scheme 25

Scheme 25: Engine Coolant Fan Shroud Replacement (LUK)
Scheme 25: Engine Coolant Fan Shroud Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LUK) . Remove and reposition the air condition compressor and condenser hose. Refer to Air Conditioning Compressor and Condenser Hose Replacement . Disconnect the drive motor battery coolant/air separator from the cooling fan shroud. Refer to Drive Motor Battery Coolant/Air Separator Replacement . Disconnect the engine coolant fan motor electrical connectors. Unclip all wiring harness that are connected to the shroud.
1Engine Coolant Fan Shroud Bolt (Qty: 2) CAUTION: Refer to Fastener Caution .
2Engine Coolant Fan Shroud
CAUTION
Refer to Fastener Caution .

Engine Coolant Fan Shroud Replacement (LUK)

Scheme 26

Scheme 26: Radiator Replacement (LKW)
Scheme 26: Radiator Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the radiator inlet and outlet hoses from the radiator. Refer to Radiator Inlet Hose Replacement (LKW) and Radiator Outlet Hose Replacement (LKW) . Remove the transmission fluid cooler inlet and outlet pipes from the radiator and the engine coolant fan shroud. Refer to Transmission Fluid Cooler Inlet Pipe Replacement (LKW) and Transmission Fluid Cooler Outlet Pipe Replacement (LKW) . Disconnect the electrical connectors from the engine coolant fan and unclip the wiring harness from the fan shroud. Lift the condenser off of the retainers on the radiator and support the air conditioning condenser. Remove the left and right radiator support brackets. Refer to Radiator Lower Bracket Replacement (LKW) . Remove the radiator and shroud as an assembly.
1Radiator Procedure Remove the engine coolant fan shroud from the radiator. Refer to Engine Coolant Fan Shroud Replacement (LKW) ,. Transfer components as necessary. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Check the cooling system for leaks. Refer to Cooling System Leak Testing .

Radiator Replacement (LKW)

Scheme 27

Scheme 27: Radiator Replacement (LUK)
Scheme 27: Radiator Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the radiator inlet hose fr Radiator Inlet Hose Replacement (LUK) . Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LUK) . Remove transmission fluid cooler inlet and outlet hoses from the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement (LUK) , and Transmission Fluid Cooler Outlet Pipe Replacement (LUK) . Reposition and secure the A/C condenser with the auxiliary radiator to the impact bar without disconnecting the lines. Refer to Air Conditioning Condenser Replacement (LUK) . Disconnect the engine coolant fan harness electrical connectors. Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement (LUK) .
1Radiator Procedure Remove the engine coolant fan shroud from the radiator. Refer to Engine Coolant Fan Shroud Replacement (LUK) .

Radiator Replacement (LUK)

  1. Drain the engine cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the engine coolant fan shroud (2) from the radiator. Refer to «Engine Coolant Fan Shroud Replacement (LTG)»(ref-609148-S41968845182014041500000) .
  3. Remove the radiator outlet hose (2) from the radiator. Refer to «Radiator Outlet Hose Replacement (LTG)»(ref-609148-S08662086932014041500000) .
  4. Remove the radiator upper brackets (3). Refer to «Radiator Upper Bracket Replacement (LTG)»(ref-609148-S14752417032014041500000) .
  5. Remove the air conditioning condenser. Refer to «Air Conditioning Condenser Replacement (LTG, LKW)»(ref-609118-S18273815282014041500000) .
  6. Remove the charge air cooler radiator (1). Refer to «Charge Air Cooler Radiator Replacement (LTG)»(ref-609171-S25509324342014041500000) .
  7. Remove the transmission fluid cooler outlet pipe from the radiator. Refer to «Transmission Fluid Cooler Outlet Pipe Replacement (LTG)»(ref-609227-S04104197292014041500000) .
  8. Remove the transmission fluid cooler inlet pipe from the radiator. Refer to «Transmission Fluid Cooler Inlet Pipe Replacement (LTG)»(ref-609227-S29851796702014041500000) .
  9. Remove the radiator air seal.
  10. Tilt the radiator (1) forward, lift up to remove the radiator assembly.
  1. Install the radiator assembly (1).
  2. Install the radiator air seal.
  3. Install the transmission fluid cooler inlet pipe to the radiator. Refer to «Transmission Fluid Cooler Inlet Pipe Replacement (LTG)»(ref-609227-S29851796702014041500000) .
  4. Install the transmission fluid cooler outlet pipe to the radiator. Refer to «Transmission Fluid Cooler Outlet Pipe Replacement (LTG)»(ref-609227-S04104197292014041500000) .
  5. Install the charge air cooler radiator (1). Refer to «Charge Air Cooler Radiator Replacement (LTG)»(ref-609171-S25509324342014041500000) .
  6. Install the air conditioning condenser. Refer to «Air Conditioning Condenser Replacement (LTG, LKW)»(ref-609118-S18273815282014041500000) .
  7. Install the radiator upper brackets (3). Refer to «Radiator Upper Bracket Replacement (LTG)»(ref-609148-S14752417032014041500000) .
  8. Install the radiator outlet hose (2) to the radiator. Refer to «Radiator Outlet Hose Replacement (LTG)»(ref-609148-S08662086932014041500000) .
  9. Install the engine coolant fan shroud (2) to the radiator. Refer to «Engine Coolant Fan Shroud Replacement (LTG)»(ref-609148-S41968845182014041500000) .
  10. Fill the engine cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  11. Check the cooling system for leaks. Refer to «Cooling System Leak Testing»(ref-609148-S13807576842014041500000) .

Scheme 28

Scheme 28: Radiator Support Bracket Replacement (LUK)
Scheme 28: Radiator Support Bracket Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Support the radiator.
1Radiator Support Bracket Fastener (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 25 N.m (18 lb ft)
2Radiator Support Bracket (Qty: 2)
CAUTION
Refer to Fastener Caution .

Radiator Support Bracket Replacement (LUK)

Scheme 29

Scheme 29: Radiator Support Bracket Replacement (LTG)
Scheme 29: Radiator Support Bracket Replacement (LTG)
CalloutComponent Name
Preliminary Procedures Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . Remove the radiator air side baffle and deflector retainers from the radiator lower bracket. Support the radiator assembly.
1Radiator Support Bracket Fastener (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 22 (16 lb ft)
2Radiator Support Bracket (Qty: 2) Procedure Remove the front bumper lower impact bar bracket and transfer all parts.
CAUTION
Refer to Fastener Caution .

Radiator Support Bracket Replacement (LTG)

Scheme 30

Scheme 30: Radiator Air Side Baffle and Deflector Replacement (Right LKW)
Scheme 30: Radiator Air Side Baffle and Deflector Replacement (Right LKW)
CalloutComponent Name
Preliminary Procedures Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . Remove the air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement (LTG) .
1Radiator Air Side Baffle and Deflector Retainer (Qty: 3)
2Radiator Air Side Baffle and Deflector Retainer CAUTION: Refer to Fastener Caution .
3Radiator Air Side Baffle and Deflector
CAUTION
Refer to Fastener Caution .

Radiator Air Side Baffle and Deflector Replacement (Right LKW)

Scheme 31

Scheme 31: Radiator Air Side Baffle and Deflector Replacement (Left LKW)
Scheme 31: Radiator Air Side Baffle and Deflector Replacement (Left LKW)
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
1Radiator Air Side Baffle and Deflector Retainer (Qty: 3)
2Radiator Air Side Baffle and Deflector Retainer CAUTION: Refer to Fastener Caution .
3Radiator Air Side Baffle and Deflector Procedure Remove the electrical wiring harness retaining clips from the radiator air side baffle and deflector.
CAUTION
Refer to Fastener Caution .

Radiator Air Side Baffle and Deflector Replacement (Left LKW)

Scheme 32

Scheme 32: Radiator Air Side Baffle and Deflector Replacement (Left LUK)
Scheme 32: Radiator Air Side Baffle and Deflector Replacement (Left LUK)
CalloutComponent Name
Preliminary Procedures Remove the front fascia. Refer to Front Bumper Fascia Replacement
1Radiator Air Side Baffel and Deflector Retainers (Qty 3)
2Radiator Air Side Baffel and Deflector

Radiator Air Side Baffle and Deflector Replacement (Left LUK)

Scheme 33

Scheme 33: Radiator Air Side Baffle and Deflector Replacement (Right LUK)
Scheme 33: Radiator Air Side Baffle and Deflector Replacement (Right LUK)
CalloutComponent Name
Preliminary Procedures Remove the front fascia. Refer to Front Bumper Fascia Replacement .
1Radiator Air Side Baffle and Deflector Retainer (Qty: 3)
2Radiator Air Side Baffle and Deflector

Radiator Air Side Baffle and Deflector Replacement (Right LUK)

Scheme 34

Scheme 34: Radiator Air Side Baffle and Deflector Replacement (Left LTG)
Scheme 34: Radiator Air Side Baffle and Deflector Replacement (Left LTG)
CalloutComponent Name
Preliminary Procedures Remove the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement .
1Radiator Air Side Baffle and Deflector Retainer
2Radiator Air Side Baffle and Deflector Retainer
3Radiator Air Side Baffle and Deflector Procedure Remove the electrical harness anti rotation clip.

Radiator Air Side Baffle and Deflector Replacement (Left LTG)

Scheme 35

Scheme 35: Radiator Air Side Baffle and Deflector Replacement (Right LTG)
Scheme 35: Radiator Air Side Baffle and Deflector Replacement (Right LTG)
CalloutComponent Name
Preliminary Procedures Remove the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement . Air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement (LTG) .
1Radiator Air Side Baffle and Deflector Retainer
2Radiator Air Side Baffle and Deflector Retainer
3Radiator Air Side Baffle and Deflector

Radiator Air Side Baffle and Deflector Replacement (Right LTG)

Scheme 36

Scheme 36: Radiator Air Upper Baffle and Deflector Replacement (LKW)
Scheme 36: Radiator Air Upper Baffle and Deflector Replacement (LKW)
CalloutComponent Name
Preliminary Procedure Remove the front fascia. Refer to Front Bumper Fascia Replacement .
1Radiator Air Upper Baffle and Deflector Retainers (Qty 5)
2Radiator Air Upper Baffle and Deflector

Radiator Air Upper Baffle and Deflector Replacement (LKW)

Radiator Air Upper Baffle and Deflector Replacement (LTG)

CalloutComponent Name
Preliminary Procedure Remove the front fascia. Refer to Front Bumper Fascia Replacement .
1Radiator Air Upper Baffle and Deflector Retainers (Qty 5)
2Radiator Air Upper Baffle and Deflector

Radiator Air Upper Baffle and Deflector Replacement (LTG)

Scheme 37

Scheme 37: Radiator Air Upper Baffle and Deflector Replacement (LUK)
Scheme 37: Radiator Air Upper Baffle and Deflector Replacement (LUK)
CalloutComponent Name
Preliminary Procedures Remove the front fascia. Refer to Front Bumper Fascia Replacement . Remove the air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement .
1Radiator Air Upper Baffle and Deflector Retainers (Qty 4)
2Radiator Air Upper Baffle and Deflector

Radiator Air Upper Baffle and Deflector Replacement (LUK)

Scheme 38

Scheme 38: Coolant Heater Replacement (LUK)
Scheme 38: Coolant Heater Replacement (LUK)
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Engine Coolant Heater Cord
2Coolant Heater Fastener CAUTION: Refer to Fastener Caution . Tighten 9 (80 lb in)
3Coolant Heater Procedure Disconnect the engine coolant heater cord. Remove the fastener security retainer. Remove the coolant heater.
CAUTION
Refer to Fastener Caution .

Coolant Heater Replacement (LUK)

Scheme 39

Scheme 39: Coolant Heater Replacement (LKW)
Scheme 39: Coolant Heater Replacement (LKW)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) . Remove the starter. Refer to Starter Replacement (LKW) .
1Engine Coolant Heater CAUTION: Refer to Component Fastener Tightening Caution . Procedure Disconnect the engine coolant heater cord. Tighten 50 (37 lb ft)
CAUTION
Refer to Component Fastener Tightening Caution .

Coolant Heater Replacement (LKW)

Scheme 40

Scheme 40: Coolant Heater Cord Replacement (LTG)
Scheme 40: Coolant Heater Cord Replacement (LTG)
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Coolant Heater Connector
2Coolant Heater Cord NOTE: Observe how the coolant heater cord was routed within the engine compartment.
NOTE
Observe how the coolant heater cord was routed within the engine compartment.

Coolant Heater Cord Replacement (LTG)

Scheme 41

Scheme 41: Coolant Heater Cord Replacement (LUK)
Scheme 41: Coolant Heater Cord Replacement (LUK)
CalloutComponent Name
1Coolant Heater Connector
2Coolant Heater Cord

Coolant Heater Cord Replacement (LUK)

Scheme 42

Scheme 42: Coolant Heater Cord Replacement (LKW)
Scheme 42: Coolant Heater Cord Replacement (LKW)
CalloutComponent Name
Preliminary Procedure Remove the starter. Refer to Starter Replacement (LKW) .
1Coolant Heater Cord NOTE: Observe how the coolant heater cord was routed within the engine compartment.
NOTE
Observe how the coolant heater cord was routed within the engine compartment.

Coolant Heater Cord Replacement (LKW)

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