Engine Cooling System Chevrolet Monte Carlo VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Scheme 1

Scheme 2

Cooling System Connector End Views

Cooling Fan - Left Connector End Connector Part Information 12033769 2-Way F Metri-Pack 630 Series, Pull to Seat (BLK) Pin Wire Color Circuit No. Function A BLK 250 Ground B LT BLU 409 Cooling Fan Motor Supply Voltage

Cooling Fan - Right Connector End Connector Part Information 12033769 2-Way F Metri-Pack 630 Series, Pull to Seat (BLK) Pin Wire Color Circuit No. Function A WHT 504 Cooling Fan Low Reference B GRY 532 Cooling Fan Motor Supply Voltage

Diagnostic Starting Point - Engine Cooling

Begin the system diagnosis with the Diagnostic System Check - Engine Cooling . The Diagnostic System Check 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.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

1. 2: Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition.
2. 3: Determine if the Instrument Cluster or Powertrain Control Modules have set DTCs which may affect Engine Cooling operation are present.
3. 4: The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed.

Diagnostic System Check - Engine Cooling

Scan Tool Output Controls

Powertrain Control Module (PCM) Scan Tool Output Controls

Scan Tool Data List

Powertrain Control Module (PCM) Scan Tool Data List (3.4 Liter LA1)

Powertrain Control Module (PCM) Scan Tool Data List (3.8 Liter L36)

Diagnostic Trouble Code (DTC) List

Diagnostic Trouble Code (DTC) List

Circuit Description

1. P0480 - low speed cooling fan relay control circuit.
2. P0481 - high speed cooling fan relay control circuit.

Battery positive voltage is supplied to the FAN CONT #1 relay from the FAN CONT #1 fuse. The powertrain control module (PCM) controls the FAN CONT #1 relay by grounding the low speed cooling fan relay control circuit through an internal solid state device called a driver.

Battery positive voltage is supplied to the FAN CONT #2 relay and the FAN CONT #3 relay from the FAN CONT #2 and FAN CONT #3 fuse. The PCM controls the relays by grounding the high speed cooling fan relay control circuit.

When the PCM is commanding a relay on, the voltage potential of the control circuit should be low, near 0 volts. When the PCM is commanding the control circuit to a relay, the voltage potential of the 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 PCM will monitor the control circuit for the following

1. A short to ground
2. A short to voltage
3. An open circuit
4. An open relay coil
5. An internally shorted or excessively low resistance relay coil

When the PCM detects any of the above conditions, the DTC will set and the affected driver will be disabled.

Conditions for Running the DTC

1. The ignition is ON.
2. System voltage is between 9-18 volts.
3. The relay control circuit is transitioned from OFF to ON or ON to OFF.

Conditions for Setting the DTC

1. An improper voltage level has been detected on the cooling fan relay control circuit.
2. The above conditions are present for at least 30 seconds.

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. The DTC can be cleared by using the scan tool.

Diagnostic Aids

1. If the condition is not present, refer to «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#wiring-systems-introduction__testing-for-intermittent-conditions-and-poor) in Wiring Systems.
2. Review the Freeze/Failure Records vehicle mileage since the diagnostic test last 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 FAN CONT #1 relay operates. Command both the ON and OFF states. Repeat the commands as necessary.
2. 3: Listen for an audible click when the FAN CONT #2 and FAN CONT #3 relays operate. Command both the ON and OFF states. Repeat the commands as necessary.
3. 4: Tests for voltage at the coil side of the FAN CONT #1 relay. The FAN CONT #1 fuse supplies battery positive voltage to the coil side of the FAN CONT #1 relay.

DTC P0480 Or P0481

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/monte-carlo/vi-1999-2007/remont/body-electrical/#wiring-systems-introduction__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/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__engine-coolant-temperature-indicator-always-on)
2. «Cooling Fan Always On»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__cooling-fan-always-on)
3. «Cooling Fan Inoperative»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__cooling-fan-inoperative)
4. «Coolant Heater Inoperative»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__coolant-heater-inoperative)
5. «Engine Overheating»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating)
6. «Loss of Coolant»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant)
7. «Thermostat Diagnosis (Overheating)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__thermostat-diagnosis-overheating) or «Thermostat Diagnosis (Slow to heat)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__thermostat-diagnosis-slow-to-heat)
8. «Engine Fails To Reach Normal Operating Temperature»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__engine-fails-to-reach-normal-operating)

Engine Coolant Temperature Indicator Always On

Engine Coolant Temperature Indicator Always On

Cooling Fan Always On

Cooling Fan Always On

Cooling Fan Inoperative

Cooling Fan Inoperative

Engine Overheating

Engine Overheating

Loss of Coolant

Loss Of Coolant

Thermostat Diagnosis (Overheating)

Thermostat Diagnosis (Overheating)

Thermostat Diagnosis (Slow to heat)

Thermostat Diagnosis (Slow To Heat)

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

J 24460-01 Cooling System Pressure Tester. See Special Tools .

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 in order to test the pressure cap. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
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»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) . 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

J 24460-01 Cooling System Pressure Tester. See Special Tools .

1. Remove the pressure cap.
2. Test the operation of the pressure cap. Refer to «Pressure Cap Testing»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__pressure-cap-testing) .
3. Wash the pressure cap mating surface with water.
4. Use the J 24460-01 in order to apply pressure to the cooling system. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) . 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.

Draining Procedure

1. Park the vehicle on a level surface.
2. Remove the coolant pressure cap.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Place a drain pan under the drain cock.
5. Open the radiator drain cock.
6. Drain the cooling system.
7. If a complete engine block drain is required, remove the engine block drain plug.
8. Inspect the coolant.
9. 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»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__flushing) .

Filling Procedure

Tools Required

J 23688 Coolant and Battery Fluid Tester. See Special Tools .

1. Close the radiator drain cock. Tighten: Tighten the radiator drain cock to 2 N.m (18 lb in).
2. If the engine block drain plug was removed, perform the following: Apply pipe sealer to the drain plug. Install the drain plug. Tighten: Tighten the drain plug to 22 N.m (16 lb ft).
3. Lower the vehicle.
4. Open the cooling system bleeder screws.
5. Slowly fill the cooling system with a 50/50 coolant mixture.
6. Close the cooling system bleeder screws.
7. Install the coolant pressure cap.
8. Start the engine.
9. Run the engine at 2,000 - 2,500 RPM until the engine reaches normal operating temperature.
10. Allow the engine to idle for 3 minutes.
11. Shut the engine off.
12. Allow the engine to cool.
13. Top off the coolant as necessary.
14. Inspect the concentration of the engine coolant. Using the J 23688 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
15. Rinse away any excess coolant from the engine and the engine compartment.
16. Inspect the cooling system for leaks.

Flushing

Store used coolant in a properly labeled container. Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical. Do not dispose of coolant into the sewer system or ground water. This is illegal and ecologically unsound.

Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a back flusher, follow the manufacturer's instruction.

When the cooling system becomes contaminated, the cooling system should be flushed thoroughly to remove the contaminants before the engine is seriously damaged.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Clean and flush the coolant recovery reservoir with clean, drinkable water.
4. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Follow the drain and fill procedure using only clean, drinkable water. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Run the engine for 20 minutes.
7. Stop the engine.
8. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Repeat the procedure if necessary, until the fluid is nearly colorless.
10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#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.

Removal Procedure

1. Remove the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
2. Reposition the reservoir hose clamp (1).
3. Remove the reservoir hose from the radiator overflow neck.
4. Remove the coolant recovery reservoir nuts (2) from the shock tower studs.
5. Remove the coolant recovery reservoir (3) from the lower retainer and the shock tower studs.
6. Drain the coolant from the recovery reservoir in to a clean container.

Installation Procedure

1. Install the coolant recovery reservoir (3) onto the lower retainer and the shock tower studs.
2. Install the coolant recovery reservoir nuts (2) to the shock tower studs. Tighten: Tighten the nuts to 3.3 N.m (29 lb in).
3. Lubricate the reservoir hose with clean water. Route the hose to the radiator overflow neck fitting.
4. Install the coolant reservoir hose (1) to the overflow neck fitting.
5. Install the reservoir hose and clamp (1), with the clamp tabs at the 11 o'clock position, to the radiator overflow fitting on the radiator filler neck. The hose end must be flush against the radiator filler neck. Seat the clamp squarely between the radiator filler neck and the flared end of the fitting.
6. Install the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
7. Fill the coolant recovery reservoir to the proper level.

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the left diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the radiator inlet hose (1) from the water outlet housing.
5. Use the J 38185 in order to reposition the hose clamp from the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Remove the radiator inlet hose from the radiator and the vehicle.

1. Align the marks on the hose. Install the radiator inlet hose to the radiator.
2. Use the J 38185 in order to reposition and install the hose clamp to the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. Install the radiator inlet hose (1) to the water outlet housing.
4. Use the J 38185 in order to reposition and install the inlet hose to the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
5. Install the left diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the left diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Use the J 38185 in order to reposition the hose clamp from the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the radiator inlet hose from the radiator.
5. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Remove the radiator inlet hose from the water outlet housing and the vehicle.

1. Align the marks on the hose. Install the radiator inlet hose to the water outlet housing.
2. Use the J 38185 in order to reposition and install the hose clamp to the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. Install the radiator inlet hose to the radiator.
4. Use the J 38185 in order to reposition and install the hose clamp to the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
5. Install the left diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Use J 38185 in order to reposition the hose clamp from the water pump housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. Remove the radiator outlet hose (2) from the water pump housing.
4. Remove the lower radiator air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Use the J 38185 in order to reposition the hose clamp from the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Remove the radiator outlet hose from the radiator.

1. Align the marks on the hose. Install the outlet hose to the radiator.
2. Use J 38185 in order to reposition the hose clamp to the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. Install the radiator lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Install the radiator outlet hose to the water pump housing (2).
5. Use J 38185 in order to reposition the hose clamp to the water pump housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the lower radiator air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Use the J 38185 in order to reposition the hose clamp from the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the radiator outlet hose (3) from the radiator (2).
5. Lower the vehicle.
6. Use J 38185 in order to reposition the hose clamp from the water pump housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
7. Remove the radiator outlet hose from the water pump housing.

1. Align the marks on the hose. Install the radiator outlet hose to the water pump housing.
2. Use J 38185 in order to reposition the hose clamp to the water pump housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Install the radiator outlet hose (3) to the radiator (2).
5. Use J 38185 in order to reposition the hose clamp to the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Install the lower radiator air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the air cleaner intake duct.
2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the throttle body inlet hose clamp and the hose (3) from the coolant pipe.
4. Remove the throttle body inlet hose clamp and the hose (3) from the throttle body and the vehicle.

1. Install the throttle body inlet hose (3) and the hose clamp to the throttle body.
2. Install the throttle body inlet hose (3) and the hose clamp to the coolant pipe.
3. Install the air cleaner intake duct.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the air cleaner intake duct.
2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the throttle body outlet hose clamp and the hose (4) from the coolant pipe.
4. Remove the throttle body outlet hose clamp and the hose (4) from the throttle body and the vehicle.

1. Install the throttle body outlet hose (4) and the hose clamp to the throttle body.
2. Install the throttle body outlet hose (4) and the hose clamp to the coolant pipe.
3. Install the air cleaner intake duct.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

J 42971 Quick Connect Release Tool. See Special Tools .

1. Lubricate and carefully insert the appropriate end of J 42971 behind the release collar. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
2. Pull the hose assembly (1) out of the mating connector (3).
3. Inspect the male fitting (1), the female fitting (3), and the release collar (2) for the following conditions: Nicks Scratches Flat spots Damaged O-rings Damaged release collar
4. If any of the above conditions exist replace the appropriate part.

1. Align the male fitting (1) with the female fitting (3).
2. Push the fittings together until a definite snap and a solid stop are felt.
3. Add the proper amount of engine oil.

1. Remove the engine oil cooler from the vehicle. Refer to «Engine Oil Cooler Replacement - Auxiliary»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the right engine splash shield. Refer to «Splash Shield Replacement - Engine - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Remove the engine oil cooler lines from the engine oil filter adapter. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the engine oil cooler line mounting bolt (1).
5. Remove the engine oil cooler line mounting block (2).
6. Cut and remove the tie strap that holds the engine oil cooler lines to the frame.
7. Remove the engine oil cooler lines from the vehicle.

1. Install the engine oil cooler lines to the vehicle.
2. Install the engine oil cooler to the vehicle. Refer to «Engine Oil Cooler Replacement - Auxiliary»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Install the engine oil cooler lines to the engine oil filter adapter. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Install the engine oil cooler line mounting block (2) to the engine oil cooler lines.
6. Install the bolt (1) through the engine oil cooler line mounting block. Tighten: Tighten the bolt to 3.4 N.m (30 lb in).
7. Install a new tie strap around the engine oil cooler lines and frame.
8. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
9. Add the proper amount of engine oil.

1. Remove the radiator air baffle retainers.
2. Tilt the rear of the air baffle upward slightly. Slide the air baffle rearward in order to disengage the upper and lower clips of the air baffle from the fascia support.
3. Remove the radiator air baffle.
4. Remove the upper bolt from the engine oil cooler.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the 2 lower bolts from the engine oil cooler.
7. Lower the engine oil cooler below the front bumper.
8. Remove the engine oil cooler line block connector (3) from the engine oil cooler lines.
9. Remove the oil cooler lines from the engine oil cooler. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Install the engine oil cooler lines to the engine oil cooler. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Install the engine oil cooler line block connector (3) to the engine oil cooler lines.
3. Install the bolt through the engine oil cooler block connector and install nut. Tighten: Tighten the bolt to 3.4 N.m (30 lb in).
4. Install the engine oil cooler to the vehicle.
5. Install the 2 lower bolts to the engine oil cooler. Tighten: Tighten the bolts to 2 N.m (18 lb in).
6. Install the upper bolt to the engine oil cooler. Tighten: Tighten the bolt to 2 N.m (18 lb in).
7. Lower the vehicle.
8. Position the radiator air baffle to the vehicle. Tilt the rear of the air baffle upward slightly. Position the upper clip of the air baffle to the lower edge of the front fascia support C-channel.
9. Slide the baffle towards the front of the vehicle in order to completely engage the upper and lower clips of the baffle onto the fascia support.
10. Align the tabs at the rear of the air baffle to the openings in the upper radiator support.
11. Install the radiator air baffle retainers.
12. Add the proper amount of engine oil.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Disconnect the cooling fans electrical connector.
3. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the right and the left engine mount struts. Refer to the following procedures: «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1) «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1) in Engine Mechanical-3.4L «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L
5. Remove the left front fender upper diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
6. Remove the radiator inlet hose from the radiator.
7. Remove the air cleaner assembly.
8. Remove the PCM harness from the fan shroud clip.
9. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
10. Remove the push pin retainer from the lower left side of the fan shroud.
11. Remove the transmission oil cooler lines from the retainer clip at the bottom of the cooling fan shroud.
12. Lower the vehicle.
13. Remove the cooling fan shroud bolts.
14. Disengage the cooling fan shroud clip from the top of the radiator.
15. Remove the radiator upper support brackets and bolts that connect to the fan shroud.
16. Remove the cooling fans electrical harness from the fan shroud clips.
17. Remove the cooling fan shroud.

1. Install the cooling fan shroud.
2. Install the cooling fans electrical harness to the fan shroud clips.
3. Connect the cooling fans electrical connector.
4. Install the cooling fan shroud clip to the top of the radiator. Apply pressure in order to completely engage the clip onto the radiator.
5. Install the cooling fan shroud bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the radiator upper support brackets and bolts that connect to the fan shroud. Tighten: Tighten the bolts to 10 N.m (89 lb in).
7. Install the air cleaner assembly.
8. Install the PCM harness on to the fan shroud clip.
9. Install the radiator inlet hose to the radiator.
10. Install the left front fender upper diagonal brace. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
11. Install the right and left engine mount struts. Refer to the following procedures: «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1) «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1) in Engine Mechanical-3.4L «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical-3.8L
12. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
13. Install the push pin retainer to the lower left side of the fan shroud.
14. Install the transmission oil cooler lines to the retainer clip at the bottom of the cooling fan shroud.
15. Lower the vehicle.
16. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
18. Inspect for proper operation.

J 38185 Hose Clamp Pliers. See Special Tools .

1. Remove the air cleaner intake duct.
2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Use the J 38185 to reposition the hose clamp from the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the radiator inlet hose from the water outlet housing.
5. Remove the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) or «Exhaust Crossover Pipe Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
6. Remove the water outlet housing bolts.
7. Remove the water outlet housing and the gasket.
8. Remove the thermostat.
9. Clean the water outlet mating surfaces.

1. Install the thermostat.
2. Install the water outlet gasket and housing.
3. Install the water outlet housing bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) or «Exhaust Crossover Pipe Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
5. Install the radiator inlet hose to the water outlet housing.
6. Use the J 38185 to reposition and install the hose clamp to the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
7. Install the air cleaner intake duct.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical - 3.8L.
2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Use the J 38185 to reposition the hose clamp from the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the radiator inlet hose from the water outlet housing.
5. Remove the water outlet housing bolt and the stud.
6. Remove the water outlet housing and the gasket.
7. Remove the thermostat.
8. Inspect and clean the water outlet housing mating surfaces.

1. Install the thermostat.
2. Install the gasket and the water outlet housing.
3. Install the water outlet housing bolt and the stud. Tighten: Tighten the bolt and the stud to 27 N.m (20 lb ft).
4. Install the radiator inlet hose to the water outlet housing.
5. Use the J 38185 to reposition install the hose clamp to the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical - 3.8L.

J 38185 Hose Clamp Pliers. See Special Tools .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner intake duct.
3. Remove the LH engine mount strut. Refer to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical - 3.4L.
4. Remove the spark plugs wires from the left side spark plugs.
5. Use the J 38185 to reposition the radiator inlet hose clamp from the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Remove the radiator inlet hose from the water outlet housing.
7. Remove the heater outlet hose (2) from the thermostat bypass pipe.
8. Remove the throttle body inlet (3) and outlet (4) hoses from the thermostat bypass pipe.
9. Remove the thermostat bypass pipe nut.
10. Remove the thermostat bypass pipe hose and clamp from the thermostat bypass pipe.
11. Remove the thermostat bypass pipe bolt.
12. Remove the thermostat bypass pipe.

1. Install the thermostat bypass pipe.
2. Install the thermostat bypass pipe bolt. Tighten: Tighten the bolt to 11 N.m (98 lb in).
3. Install the thermostat bypass pipe hose and clamp to the thermostat bypass pipe.
4. Install the thermostat bypass pipe nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
5. Install the heater outlet hose (2) and the clamp to the thermostat bypass pipe.
6. Install the throttle body inlet (3) and outlet (4) hoses and the clamps to the thermostat bypass pipe.
7. Install the radiator inlet hose to the water outlet housing.
8. Use the J 38185 to reposition and install the radiator inlet hose clamp to the water outlet housing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
9. Install the spark plugs wires to the left side spark plugs.
10. Install the LH engine mount strut. Refer to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical - 3.4L.
11. Install the air cleaner intake duct.
12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the drive belt shield bolt.
3. Remove the drive belt shield.
4. Loosen the water pump pulley bolts.
5. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1) in Engine Mechanical - 3.4L.
6. Remove the water pump pulley bolts.
7. Remove the water pump pulley.
8. Remove the water pump bolts.
9. Remove the water pump (1).
10. Remove the water pump gasket (2).
11. Clean the water pump gasket mating surfaces.

1. Install the water pump gasket (2).
2. Install the water pump (1).
3. Install the water pump bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb in).
6. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1) in Engine Mechanical - 3.4L.
7. Install the drive belt shield.
8. Install the drive belt shield bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Loosen the water pump pulley bolts.
3. Remove the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical - 3.8L.
4. Remove the water pump pulley bolts.
5. Remove the water pump pulley.
6. Remove the power steering pump and reposition. Refer to «Power Steering Pump Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-power-steering/#rack-pinion-power-steering-system) or «Power Steering Pump Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-power-steering/#rack-pinion-power-steering-system) in Power Steering System.
7. Remove the water pump bolts.
8. Remove the water pump.
9. Remove the water pump gasket.
10. Clean and inspect the water pump mating surfaces.

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the long water pump bolts to 34 N.m (25 lb ft). Tighten the short water pump bolts to 22 N.m (16 lb ft).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the bolts to 13 N.m (115 lb in).
6. Install the power steering pump. Refer to «Power Steering Pump Replacement (3.4L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-power-steering/#rack-pinion-power-steering-system) or «Power Steering Pump Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/manual-power-steering/#rack-pinion-power-steering-system) in Power Steering System.
7. Install the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) in Engine Mechanical - 3.8L.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the radiator drain plug and seal. The seal usually comes out attached to the plug.
3. Remove the body of the drain plug. Use your fingers or needlenose pliers to disengage the locking tangs from the side tank.
4. Clean the drain and the drain plug.

1. Install the seal on the drain plug stem.
2. Install the drain plug. Make sure that the body is fully seated in the side tank and that the locking tangs are engaged.
3. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Remove the battery. Refer to «Battery Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the upper diagonal brace from the right front fender. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Remove the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Use J 38185 to remove the outlet hose clamp from the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
7. Remove the outlet hose from the radiator.
8. Remove the coolant reservoir hose from the radiator overflow neck.
9. Disconnect the transaxle oil cooler pipes from the radiator.
10. Pull the plastic cap back from the quick connect fitting and down along the transaxle oil cooler line.
11. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.
12. Remove and discard the old retaining ring from the quick connect fitting.
13. Pull the transaxle oil cooler pipe straight out from the quick connect fitting.
14. Lower the vehicle.
15. Remove the radiator.

1. Install the radiator to the lower mounts.
2. Install the transaxle oil cooler pipes.
3. Install a NEW retaining ring onto the fitting.
4. Hook one of the open ends of the retaining ring into one of the slots in the quick connect fitting.
5. Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears through the 3 slots on the fitting.
6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
7. Install the transaxle oil cooler pipes into the radiator quick connect fitting.
8. Insert the ends of the pipe into the quick connect fitting until you hear or feel a click.
9. Pull back sharply on the pipe in order to ensure that the pipe is fastened into the quick connect fitting.
10. Position the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting.
11. Fully seat the plastic cap against the fitting.
12. Allow no gap between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating.
14. Install the outlet hose to the radiator.
15. Install the coolant reservoir hose to the radiator overflow neck.
16. Use J 38185 to install the outlet hose clamp to the radiator. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
17. Install the lower air deflector. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
18. Install the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
19. Install the battery. Refer to «Battery Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
20. Install the upper diagonal brace to the right front fender. Refer to «Brace Replacement - Front Fender Upper Diagonal»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
21. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
22. Adjust the transaxle fluid level.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the radiator lower air deflector bolts.
3. Remove the radiator lower air deflector.

1. Install the radiator lower air deflector.
2. Install the radiator lower air deflector bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Lower the vehicle.

1. Remove the radiator side air deflector retainers. Reposition the ambient temperature sensor.
2. Remove the radiator side air deflectors.

1. Position the radiator side air deflectors to the vehicle. Position the ambient temperature sensor to the proper location.
2. Install the radiator side air deflector retainers.

1. Remove the radiator air baffle retainers.
2. Tilt the rear of air baffle upward slightly. Slide the air baffle rearward in order to disengage the upper and lower clips of the air baffle from the fascia support.
3. Remove the radiator air baffle.

1. Position the radiator air baffle to the vehicle. Tilt the rear of the air baffle upward slightly. Position the upper clip of the air baffle to the lower edge of the front fascia support C-channel.
2. Slide the baffle towards the front of the vehicle in order to completely engage the upper and lower clips of the baffle onto the fascia support.
3. Align the tabs at the rear of the air baffle to the openings in the upper radiator support.
4. Install the radiator air baffle retainers.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the coolant heater cord from the coolant heater.
3. Remove the engine block heater screw.
4. Remove the engine block heater.
5. Clean the engine block heater opening.

1. Apply a coat of GM P/N 12346004, (Canadian P/N 10953480) thread sealant with Teflon or equivalent to the following: The engine block heater seal The cleaned surface of the engine block heater hole
2. Position the heating element at the 3 o'clock position (2).
3. Install the engine block heater.
4. Install the engine block heater screw. Tighten: Tighten the screw to 2 N.m (18 lb in).
5. Connect the coolant heater cord to the coolant heater.
6. Lower the vehicle.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the coolant heater cord from the coolant heater.
3. Loosen the bolt at the coolant heater but do not remove.
4. Remove the coolant heater.
5. Remove and clean any burrs, compound, paint, or rough spots from the core plug hole.

1. Apply a coat of GM P/N 12346004, (Canadian P/N 10953480) thread sealant with Teflon or equivalent to the O-ring and clean the surface of the plug opening.
2. Install the coolant heater by pushing tight to the block.
3. Install the coolant heater so the element is at the 9 o'clock position (2).
4. Tighten the coolant heater bolt until both locking wings draw tight against the inner wall of the engine block. Tighten: Tighten the bolt to 2 N.m (17 lb in).
5. Connect the coolant heater cord to the coolant heater.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the coolant heater cord retainer from the upper radiator support.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Cut the coolant heater cord retaining straps from the engine wiring harness.
4. Disconnect the coolant heater cord from the coolant heater.
5. Lower the vehicle.
6. Remove the coolant heater cord from the vehicle.

1. Install the coolant heater cord to the vehicle.
2. Raise the vehicle.
3. Connect the coolant heater cord to the coolant heater.
4. Install new retaining straps to the coolant heater cord and the engine wiring harness.
5. Lower the vehicle.
6. Install the coolant heater cord retainer to the upper radiator support.

1. Remove the coolant heater cord retainer from the upper radiator support.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Cut the coolant heater cord retaining straps from the engine wiring harness.
4. Disconnect the coolant heater cord from the coolant heater.
5. Lower the vehicle.
6. Remove the coolant heater cord from the vehicle.

1. Install the coolant heater cord to the vehicle.
2. Raise the vehicle.
3. Connect the coolant heater cord to the coolant heater.
4. Install new retaining straps to the coolant heater cord and the engine wiring harness.
5. Lower the vehicle.
6. Install the coolant heater cord retainer to the upper radiator support.

Cooling Fan Control 3.4L (LA1)

The engine cooling fans are controlled by the body control module (BCM) and the powertrain control module (PCM). The BCM sends a Class 2 message to the PCM requesting cooling fan operation. If there is a Class 2 communication malfunction between the BCM and the PCM. The PCM will operate the engine cooling fans independently of the BCM.

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 PCM to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the engine wiring harness junction block. The ground path is provided at G101.

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 FAN CONT #1 relay coil, closes the relay contacts, and supplies battery positive voltage from the FAN CONT #1 fuse through the cooling fan motor supply voltage circuit to the right cooling fan. The ground path for the right cooling fan is through the FAN CONT #2 relay and the left 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 FAN CONT #1 relay through the low speed cooling fan relay control circuit. After a 3-second delay, the PCM supplies a ground path for the FAN CONT #2 relay and the FAN CONT #3 relay through the high speed cooling fan relay control circuit. This energizes the FAN CONT #2 relay coil, closes the relay contacts, and provides a ground path for the right cooling fan. At the same time the FAN CONT #3 relay coil is energized closing the relay contacts and provides battery positive voltage from the FAN CONT #2 fuse on the cooling fan motor supply voltage circuit to the left cooling fan. During high speed fan operation, both engine cooling fans have there own ground path. The result is a parallel circuit with both fans running at high speed.

The BCM will request low speed cooling fan operation from the PCM under the following conditions

1. Engine coolant temperature exceeds approximately 103°C (217°F).
2. When A/C is requested and the ambient temperature is more than 10°C (50°F).
3. A/C refrigerant pressure exceeds 1310 kPa (190 psi).
4. After the vehicle is shut off if the engine coolant temperature at key-off is more than 117°C (243°F) and system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.

The BCM will request high speed cooling fan operation from the PCM under the following conditions

1. Engine coolant temperature reaches 110°C (230°F).
2. A/C refrigerant pressure exceeds 1655 kPa (240 psi).
3. When certain DTCs set.

Cooling Fan Control 3.8L (L36)

The engine cooling fans are controlled by the body control module (BCM) and the powertrain control module (PCM). The BCM sends a Class 2 message to the PCM requesting cooling fan operation. If there is a Class 2 communication malfunction between the BCM and the PCM. The PCM will operate the engine cooling fans independently of the BCM.

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 PCM to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the engine wiring harness junction block. The ground path is provided at G101.

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 FAN CONT #1 relay coil, closes the relay contacts, and supplies battery positive voltage from the FAN CONT #1 fuse through the cooling fan motor supply voltage circuit to the right cooling fan. The ground path for the right cooling fan is through the FAN CONT #2 relay and the left 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 FAN CONT #1 relay through the low speed cooling fan relay control circuit. After a 3-second delay, the PCM supplies a ground path for the FAN CONT #2 relay and the FAN CONT #3 relay through the high speed cooling fan relay control circuit. This energizes the FAN CONT #2 relay coil, closes the relay contacts, and provides a ground path for the right cooling fan. At the same time the FAN CONT #3 relay coil is energized closing the relay contacts and provides battery positive voltage from the FAN CONT #2 fuse on the cooling fan motor supply voltage circuit to the left cooling fan. During high speed fan operation, both engine cooling fans have there own ground path. The result is a parallel circuit with both fans running at high speed.

The BCM will request low speed cooling fan operation from the PCM under the following conditions

1. Engine coolant temperature exceeds approximately 100°C (212°F).
2. When A/C is requested and the ambient temperature is more than 10°C (50°F).
3. A/C refrigerant pressure exceeds 1310 kPa (190 psi).
4. After the vehicle is shut off if the engine coolant temperature at key-off is more than 117°C (243°F) and system voltage is more than 12 volts. The fans will stay on for approximately 4 minutes.

The BCM will request high speed cooling fan operation from the PCM under the following conditions

1. Engine coolant temperature reaches 105°C (221°F).
2. A/C refrigerant pressure exceeds 1655 kPa (240 psi).
3. When certain DTCs set.

Engine Coolant Indicator(s)

TEMP

1. The IPC illuminates the TEMP indicator when the PCM determines that the coolant temperature is greater than 128°C (262°F). The IPC receives a discrete input from the PCM requesting illumination.
2. The IPC performs the displays test at the start of each ignition cycle. The IPC illuminates the TEMP indicator.

Coolant Heater

The optional engine coolant heater (RPO K05) operates using 110-volt 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 system cools slowly or not at all. This allows the engine to warm quickly.

Cooling Cycle

Coolant is drawn from the radiator outlet and into the water pump inlet by the water pump. Some coolant will then be pumped from the water pump, to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost.

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

The coolant is then forced 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 it absorbs additional heat.

Coolant is also directed to the throttle body. There it circulates through passages in the casting. During initial warm-up, the coolant assists in warming the throttle body. During normal operating temperatures, the coolant assists in keeping the throttle body cool.

From the cylinder heads, the coolant is then forced to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine is warmed, or it will flow through the thermostat and into the radiator where it is cooled and the coolant cycle is completed.

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 clean drinkable 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. It consists of a core and 2 tanks. The aluminum core is a crossflow tube and fin design. This is a series of tubes that extend side to side from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer from the coolant to the atmosphere. The inlet and outlet tanks are molded with a high temperature, nylon reinforced plastic. A high temperature rubber gasket seals the tank flange edge. 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 which is located in the bottom of the left hand tank. The drain cock includes the drain cock and drain cock seal.

The radiator removes heat from the coolant passing through it. The fins on the core absorb heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.

During vehicle use, the coolant heats and expands. The coolant that is displaced by this expansion flows into the surge tank. As the coolant circulates, air is allowed to exit. This is an advantage to the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles.

Pressure Cap

The pressure cap is a cap that seals and pressurizes the cooling system. It contains a blow off or pressure valve and a vacuum or atmospheric valve. The pressure valve is held against its seat by a spring of predetermined strength, which protects the radiator by relieving pressure if it exceeds 15 psi. The vacuum valve is held against its seat by a spring, which permits opening of the valve to relieve vacuum created in the cooling system as it cools off. The vacuum, if not relieved, might cause the radiator to collapse.

The pressure cap allows pressure in the cooling system to build up. As the pressure builds, the boiling point of the coolant goes up as well. Therefore, the coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant is, the faster the heat moves from the radiator to the cooler, passing air. The pressure in the cooling system can get too high, however. When the pressure exceeds the strength of the spring, it raises the pressure valve so that the excess pressure can escape. As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open, allowing outside air into the cooling system. This equalizes the pressure in the cooling system with 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. It 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.

In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure in the cooling system gets too high, it will open the pressure valve in the pressure cap. This allows the coolant, which has expanded due to being heated, is allowed to flow through the overflow tube and into the recovery reservoir. As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum opens the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be siphoned back into the radiator. Under normal operating conditions, no coolant is lost. Although the coolant level in the recovery reservoir goes up and down, the radiator and cooling system are kept full. An advantage to using a coolant recovery reservoir is that it eliminates almost all air bubbles from the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles.

Air Baffles and Seals

The cooling system uses deflectors, air baffles and air seals to increase system cooling. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle to flow through the radiator and increase cooling. Air baffles are also used to direct airflow into the radiator and increase cooling. Air seals prevent air from bypassing the radiator and A/C condenser. Air seals also prevent recirculation of the 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. These sealed bearings never need to be lubricated. With a sealed bearing, grease cannot leak out, and dirt and water cannot get in.

The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is driven by the crankshaft via the drive belt.

Thermostat

The thermostat is a coolant flow control component. It's purpose is to regulate the operating temperature of the engine. It utilizes a temperature sensitive wax-pellet element. The element connects to a valve through a piston. When the element is heated, it expands and exerts pressure against a rubber diaphragm. This pressure forces the valve to open. As the element is cooled, it contracts. 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 it has opened. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.

Engine Oil Cooler

The engine oil cooler is a heat exchanger. It is located inside the left side end tank of the radiator. The engine oil temperature is controlled by the temperature of the engine coolant that surrounds the oil cooler in the radiator.

The engine oil pump, pumps the oil through the engine oil cooler line to the oil cooler. The oil then flows through the cooler where the engine coolant absorbs heat from the oil. The oil is then pumped through the oil cooler return line, to the oil filter, to the engine block oil system.

Transmission Oil Cooler

The transmission oil cooler is a heat exchanger. It is located inside the right side 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 down through the cooler.

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

Special Tools

Special Tools Illustration Tool Number/ Description J 23688 Coolant and Battery Fluid Tester J 24460-01 Cooling System Pressure Tester J 24731 Tempil Stick J 38185 Hose Clamp Pliers J 42971 Quick Connect Release Tool

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See also:
• Scan Tool Does Not Power Up
• Testing for Intermittent Conditions and Poor Connections
• Circuit Testing
• Wiring Repairs
• Connector Repairs
• Checking Aftermarket Accessories
• Instrument Panel Cluster (IPC) Replacement
• Drive Belt Tensioner Replacement
• Drive Belt Tensioner Replacement
• Heater Core Replacement
• 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
• Cylinder Leakage Test
• Lifting and Jacking the Vehicle
• Fastener Notice
• Brace Replacement - Cross Vehicle
• Battery Negative Cable Disconnect/Connect Procedure
• Exhaust Crossover Pipe Replacement (3.4L)
• Power Steering Pump Replacement (3.4L)
• Diagnostic System Check - Engine Cooling
• Symptoms - Engine Cooling
• Diagnostic Trouble Code (DTC) List
• Cooling System Connector End Views
• Engine Coolant Temperature Indicator Always On
• Cooling Fan Always On
• Cooling Fan Inoperative
• Coolant Heater Inoperative
• Engine Overheating
• Loss of Coolant
• Thermostat Diagnosis (Overheating)
• Thermostat Diagnosis (Slow to heat)
• Engine Fails To Reach Normal Operating Temperature
• Special Tools
• Flushing
• Cooling System Leak Testing
• Pressure Cap Testing