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Engine Cooling System: Removal & Installation Chevrolet Sonic I

Cooling System (Mechanical) 17 illustrations ~3476 words

Removal Procedure

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the radiator inlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  3. Remove the radiator inlet hose (2) from the engine.
  4. Remove the radiator inlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  5. Remove the radiator inlet hose (2) from the radiator.
  6. Remove the radiator inlet hose from the vehicle.

Installation Procedure

  1. Install the radiator inlet hose to the vehicle.
  2. Install the radiator inlet hose (2) to the radiator.
  3. Install the radiator inlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  4. Install the radiator inlet hose (2) to the engine.
  5. Install the radiator inlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .

Scheme 3

Scheme 3: Radiator Outlet Hose Replacement (LUV)
Scheme 3: Radiator Outlet Hose Replacement (LUV)
CalloutComponent Name
Preliminary Procedures Drain the engine coolant. Refer to Cooling System Draining and Filling . Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the radiator surge tank outlet hose from the radiator surge tank and position it out of the way. Refer to Radiator Surge Tank Outlet Hose Replacement (LUV) , Radiator Surge Tank Outlet Hose Replacement (LDE LUW) . Remove the PCV Pipe assembly from the turbocharger and position it out of the way. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement . Remove the front compartment front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement .
1Radiator Outlet Hose Clamp (Qty: 2) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Radiator Outlet Hose

Radiator Outlet Hose Replacement (LUV)

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the radiator outlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  3. Remove the radiator outlet hose (2) from the engine.
  4. Remove the radiator outlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  5. Remove the radiator outlet hose (2) from the radiator.
  6. Remove the radiator outlet hose from the vehicle.
  1. Install the radiator outlet hose to the vehicle.
  2. Install the radiator outlet hose (2) to the radiator.
  3. Install the radiator outlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  4. Install the radiator outlet hose (2) to the engine.
  5. Install the radiator outlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .

Scheme 4

Scheme 4: Radiator Outlet Hose Connector Replacement - Radiator Side (LUV)
Scheme 4: Radiator Outlet Hose Connector Replacement - Radiator Side (LUV)
CalloutComponent Name
Preliminary Procedures Drain the engine coolant. Refer to Cooling System Draining and Filling . Remove the front compartment front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement . Remove the radiator outlet hose from the radiator outlet hose connector and position out of the way. Refer to Radiator Outlet Hose Replacement (LUV) , Radiator Outlet Hose Replacement (LDE LUW) .
1Radiator Outlet Hose Connector Retaining Clip
2Radiator Outlet Hose Connector

Radiator Outlet Hose Connector Replacement - Radiator Side (LUV)

Scheme 5

Scheme 5: Radiator Outlet Hose Connector Replacement- Engine Side (LUV)
Scheme 5: Radiator Outlet Hose Connector Replacement- Engine Side (LUV)
CalloutComponent Name
Preliminary Procedures Drain the engine coolant. Refer to Cooling System Draining and Filling . Remove the radiator surge tank outlet hose from the radiator surge tank and position it out of the way. Refer to Radiator Surge Tank Outlet Hose Replacement (LUV) , Radiator Surge Tank Outlet Hose Replacement (LDE LUW) . Remove the PCV Pipe assembly from the turbocharger and position it out of the way. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
1Radiator Outlet Hose Connector Retaining Clip
2Radiator Outlet Hose Connector

Radiator Outlet Hose Connector Replacement- Engine Side (LUV)

  1. Disconnect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
  2. Drain engine coolant. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000)
  3. Remove the turbocharger oil feed pipe. Refer to «Turbocharger Oil Feed Pipe Replacement»(ref-542544-S40406830752013041600000) .
  4. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LUV)»(ref-542543-S28635637502013041600000) .
  5. Lower vehicle.
  6. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  7. Remove the oil cooler outlet hose clamp (2).
  8. Remove the oil cooler outlet hose (3) from the thermostat housing (1).
  9. Remove the turbocharger coolant return pipe bolt (1) from the oil cooler housing.
  10. Remove the turbocharger coolant return pipe clamp (2).
  11. Remove the turbocharger coolant return pipe (3) from the oil cooler inlet pipe.
  12. Disconnect the oil pressure indicator switch wiring harness plug.
  13. Remove the oil cooler inlet hose clamp (1) and remove the oil cooler inlet hose from the water outlet.
  14. Remove the engine oil cooler bolt (5).
  15. Remove the engine oil cooler inlet pipe bolt (4).
  16. Remove the engine oil cooler inlet pipe (2) and the seal ring (3).
  17. Raise vehicle.
  18. Remove the oil cooler outlet pipe bolt (1) from the engine block.
  19. Remove the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose.
  20. Lower vehicle.
  21. Remove the 2 oil cooler bolts (1).
  22. Raise vehicle.
  23. Remove the oil cooler (1) in compound with the oil cooler gasket (2) and the seal ring (3).
  24. Remove the oil pressure indicator switch from the oil cooler.
  1. Install the oil pressure indicator switch to the oil cooler. Use a NEW seal ring.
  2. Tighten the oil pressure indicator switch to 20 N.m (15 lb ft).
  3. Clean the sealing surfaces.
  4. Install the oil cooler (1) in compound with a NEW oil cooler gasket (2) and a NEW seal ring (3).
  5. Lower vehicle.
  6. Install the 2 oil cooler bolts (1) and hand tighten.
  7. Install the engine oil cooler inlet pipe (2) in compound with a NEW seal ring (3).
  8. Install the oil cooler inlet hose to the water outlet and install the oil cooler inlet hose clamp (1).
  9. Install the engine oil cooler bolt (5).
  10. Install the engine oil cooler inlet pipe bolt (4) and tighten to 10 N.m (89 lb in).
  11. Tighten the 3 engine oil cooler bolts to 20 N.m (15 lb ft).
  12. Install the turbocharger coolant return pipe (3) to the oil cooler inlet pipe.
  13. Install the turbocharger coolant return pipe clamp (2).
  14. Install turbocharger coolant return pipe bolt (1) and tighten to 10 N.m (89 lb in).
  15. Connect the oil pressure indicator switch wiring harness plug.
  16. Raise vehicle.
  17. Install the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose to the oil cooler.
  18. Install the oil cooler outlet pipe bolt (1) to the engine block and tighten to 10 N.m (89 lb in).
  19. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LUV)»(ref-542543-S28635637502013041600000) .
  20. Install the oil cooler outlet hose (3) to the thermostat housing (1).
  21. Install the oil cooler outlet hose clamp (2).
  22. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  23. Install the turbocharger oil feed pipe and the exhaust manifold heat shield. Refer to «Turbocharger Oil Feed Pipe Replacement»(ref-542544-S40406830752013041600000) .
  24. Connect battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
  25. Fill engine coolant. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .

Scheme 6

Scheme 6: Engine Oil Cooler Outlet Hose Replacement (LUV)
Scheme 6: Engine Oil Cooler Outlet Hose Replacement (LUV)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling . Disconnect the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LUV) , Radiator Outlet Hose Replacement (LDE LUW) .
1Engine Oil Cooler Outlet Hose Clamps (Qty: 2)
2Engine Oil Cooler Outlet Hose

Engine Oil Cooler Outlet Hose Replacement (LUV)

Scheme 7

Scheme 7: Engine Oil Cooler Coolant Inlet Hose Replacement (LUV)
Scheme 7: Engine Oil Cooler Coolant Inlet Hose Replacement (LUV)
CalloutComponent Name
Preliminary Procedure Open the hood. Drain the cooling system. Refer to Cooling System Draining and Filling .
1Oil Cooler Inlet Hose Clamp Procedure Place a drain pan below the vehicle. Remove / install engine coolant air bleed hose clamp.
2Oil Cooler Inlet Hose Clamp Procedure Place a drain pan below the vehicle. Remove / install engine coolant air bleed hose clamp.
3Oil Cooler Inlet Hose

Engine Oil Cooler Coolant Inlet Hose Replacement (LUV)

Scheme 8

Scheme 8: Engine Oil Cooler Pipe Replacement (LUW)
Scheme 8: Engine Oil Cooler Pipe Replacement (LUW)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling . Remove the exhaust manifold with catalytic converter. Refer to Exhaust Manifold with Catalytic Converter Replacement (LUW) .
1Engine Oil Cooler Outlet Pipe Fasteners (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 8 N.m (71 lb in)
2Seals NOTE: Replace with NEW seals.
3Engine Oil Cooler Outlet Pipe
CAUTION
Refer to Fastener Caution .
NOTE
Replace with NEW seals.

Engine Oil Cooler Pipe Replacement (LUW)

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the exhaust manifold with catalytic converter. Refer to «Exhaust Manifold with Catalytic Converter Replacement (LUW)»(ref-542543-S18136445522013041600000) .
  3. Remove the engine oil cooler pipe bolts (1) and the engine oil cooler pipe (2).
  4. Remove the engine oil cooler outlet pipe bolts (1) and the engine oil cooler outlet pipe bracket (2).
  5. Remove the engine oil cooler assembly bolts (1) and remove the cooler (2).
  6. Remove the engine oil cooler inlet pipe (4) and seals (3).
  1. Replace the seals on the engine oil cooler outlet pipe and the engine oil cooler pipe.
  2. Install the engine oil cooler inlet pipe (4) with NEW seals (3) to the engine oil cooler assembly.
  3. Position the engine oil cooler assembly (2) to the engine block.
  4. Install the engine oil cooler assembly bolts (1) and tighten to 25 N.m (19 lb ft).
  5. Install the engine oil cooler outlet pipe mounting bolts (1) and the bracket (2) to the water pump housing and tighten to 8 N.m (71 lb in).
  6. Install the engine oil cooler pipe (3) to the thermostat housing and tighten bolts (1) to 8 N.m (71 lb in).
  7. Install the exhaust manifold with catalytic converter. Refer to «Exhaust Manifold with Catalytic Converter Replacement (LUW)»(ref-542543-S18136445522013041600000) .
  8. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  9. Start the engine and check for coolant leaks.

Scheme 9

Scheme 9: Engine Oil Cooler Outlet Pipe Replacement (LUW)
Scheme 9: Engine Oil Cooler Outlet Pipe Replacement (LUW)
CalloutComponent Name
Preliminary Procedure Remove the engine oil cooler pipe. Refer to Engine Oil Cooler Pipe Replacement (LUW) .
1Engine Oil Cooler Outlet Pipe Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 8 N.m (71 lb in)
2Seals NOTE: Replace with NEW seals.
3Engine Oil Cooler Outlet Pipe
CAUTION
Refer to Fastener Caution .
NOTE
Replace with NEW seals.

Engine Oil Cooler Outlet Pipe Replacement (LUW)

  1. Unclip transmission cooler lines from shroud if equipped.
  2. Unclip radiator surge tank outlet hose from fan shroud.
  3. Disconnect the engine coolant fan wiring harness.
  4. Unclip the engine coolant fan shroud (1) at the shown four mounting points.
  5. Remove the engine coolant fan shroud (1).
  6. Remove the engine coolant fan resistor (1) by unclipping the retainer clip (2).
  7. Unclip the engine coolant fan to engine coolant fan resistor wiring harness (arrows).
  8. Remove the 3 engine coolant fan engine bolts (3) from the engine coolant fan.
  9. Remove the engine coolant fan.
  1. Install the engine coolant fan.
  2. Install the 3 engine coolant fan engine bolts (3) to the engine coolant fan and tighten to 4 N.m (35 lb in).
  3. Clip in the engine coolant fan to the engine coolant fan resistor wiring harness (arrows).
  4. Install the engine coolant fan resistor (1) by clipping the retainer clip (2).
  5. Install the engine coolant fan shroud (1).
  6. Clip in the engine coolant fan shroud (1) at the shown four mounting points.
  7. Connect the engine coolant fan wiring harness.
  8. Clip the radiator surge tank outlet hose to the fan shroud.
  9. Clip the transmission cooler lines to the fan shroud if equipped.

Scheme 10

Scheme 10: Engine Coolant Fan Replacement (LUV)
Scheme 10: Engine Coolant Fan Replacement (LUV)
CalloutComponent Name
Preliminary Procedure Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LDE LUW) , Engine Coolant Fan Shroud Replacement (LUV) .
1Engine Coolant Fan Motor Electrical Harness Connector Fastener CAUTION: Refer to Fastener Caution .
2Engine Coolant Fan Motor Fastener (Qty: 3)
3Engine Coolant Fan Motor Assembly
CAUTION
Refer to Fastener Caution .

Engine Coolant Fan Replacement (LUV)

Scheme 11

Scheme 11: Turbocharger Coolant Feed Pipe Replacement (LUV)
Scheme 11: Turbocharger Coolant Feed Pipe Replacement (LUV)
CalloutComponent Name
Preliminary Procedure Remove the turbocharger. Refer to Turbocharger Replacement .
1Turbocharger Fastener CAUTION: Refer to Fastener Caution . Procedure Replace seals with NEW seals. Tighten 8 N.m (71 lb in)
2Turbocharger Coolant Feed Pipe
CAUTION
Refer to Fastener Caution .

Turbocharger Coolant Feed Pipe Replacement (LUV)

Scheme 12

Scheme 12: Turbocharger Coolant Return Pipe Replacement (LUV)
Scheme 12: Turbocharger Coolant Return Pipe Replacement (LUV)
CalloutComponent Name
Preliminary Procedure Remove the turbocharger. Refer to Turbocharger Replacement .
1Turbocharger Fastener CAUTION: Refer to Fastener Caution . Procedure Replace seals with NEW seals. Tighten 8 N.m (71 lb in)
2Turbocharger Coolant Return Pipe
CAUTION
Refer to Fastener Caution .

Turbocharger Coolant Return Pipe Replacement (LUV)

  1. Remove the battery tray. Refer to «Battery Tray Replacement»(ref-542503-S09850153572013041600000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
  3. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  4. Disconnect the engine harness connector (1) and harness fasteners (2) from the engine harness bracket, attached to the thermostat housing.
  5. Disconnect the throttle body heater inlet hose (1) and the electrical connectors (2) from the thermostat housing.
  6. Remove the engine harness bracket nut (3) and bracket (4) from the thermostat housing.
  7. Remove the radiator inlet hose (2) from the engine coolant thermostat housing.
  8. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to «Heater Outlet Hose Replacement (LUV)»(ref-542551-S12091355482013041600000) , «Heater Outlet Hose Replacement (LDE, LUW)»(ref-542551-S18377013402013041600000) .
  9. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to «Heater Inlet Hose Replacement (LDE, LUW)»(ref-542551-S01214517192013041600000) , «Heater Inlet Hose Replacement (LUV)»(ref-542551-S14895214842013041600000) .
  10. Remove the engine oil cooler outlet pipe bolts (1).
  11. Remove the engine oil cooler outlet pipe (2) from the engine coolant thermostat housing.
  12. Remove the engine coolant thermostat housing mounting bolts (1) and discard the seal (2).
  13. Remove the engine coolant thermostat housing (3) from the engine.
  1. Clean the sealing surface.
  2. Install a NEW engine coolant thermostat housing seal (2).
  3. Loosely install the engine coolant thermostat housing mounting bolts (1).
  4. Tighten the 4 engine coolant thermostat housing bolts to 8 N.m (71 lb in) in sequence (1-2-3-4).
  5. Install NEW engine oil cooler pipe seals (4, 7).
  6. Install the engine oil cooler pipe (5).
  7. Install the 2 engine oil cooler pipe bolts (6) and tighten to 8 N.m (71 lb in).
  8. Install the heater inlet hose to the engine coolant thermostat housing. Refer to «Heater Inlet Hose Replacement (LDE, LUW)»(ref-542551-S01214517192013041600000) , «Heater Inlet Hose Replacement (LUV)»(ref-542551-S14895214842013041600000) .
  9. Install the heater outlet hose to the engine coolant thermostat housing. Refer to «Heater Outlet Hose Replacement (LUV)»(ref-542551-S12091355482013041600000) , «Heater Outlet Hose Replacement (LDE, LUW)»(ref-542551-S18377013402013041600000) .
  10. Connect the electrical connectors (2) to the engine coolant thermostat housing.
  11. Install the throttle body heater inlet hose (1) to the engine coolant thermostat housing.
  12. Install the engine coolant thermostat housing bracket (4) and nut (3) and tighten to 6 N.m (53 lb in).
  13. Install the radiator inlet hose (2) to the engine coolant thermostat housing.
  14. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  15. Install the battery tray. Refer to «Battery Tray Replacement»(ref-542503-S09850153572013041600000) .
  16. Start the engine and check for coolant leaks.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  3. Remove the engine coolant temperature sensor connector (1).
  4. Disconnect the radiator outlet hose connector (2) from the engine coolant thermostat and reposition. Refer to «Radiator Outlet Hose Connector Replacement- Engine Side (LUV)»(ref-542500-S00219145922013041600000) .
  5. Remove the water inlet pipe mounting fasteners (1).
  6. Remove the water inlet seal (3) and discard.
  7. Remove the thermostat (4).
  1. Clean the sealing surface.
  2. Install the engine thermostat (4) into the water inlet pipe (2) with a NEW seal (3).
  3. Tighten the water inlet pipe mounting fasteners (1) to 9 N.m (80 lb in).
  4. Install the radiator outlet hose connector (2) to the engine coolant thermostat. Refer to «Radiator Outlet Hose Connector Replacement- Engine Side (LUV)»(ref-542500-S00219145922013041600000) .
  5. Connect the engine coolant temperature sensor connector (1).
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  8. After repairs, inspect cooling system for leaks.
  1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
  2. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  3. Disconnect the engine wiring harness connector (1) and retainers (2).
  4. Remove the wiring harness bracket nut (3) and bracket (4).
  5. If equipped, disconnect the thermostat heating element sensor (1) and remove the radiator inlet hose (2).
  6. Remove the thermostat housing retaining bolts (1).
  7. Remove the thermostat (1) and discard the seal (2).
  1. Fit the thermostat (1) to the thermostat housing using a NEW seal (2).
  2. Install the thermostat (2) and tighten the thermostat bolts (1) to 10 N.m (89 lb in).
  3. Install the radiator inlet hose (2) and connect the thermostat heating element sensor (1).
  4. Install the wiring harness bracket (4) and tighten the nut (3) to 10 N.m (89 lb in).
  5. Connect the engine harness connector (1) and harness retainers (2) to the bracket.
  6. Refill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  7. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-542503-S08263741182013041600000) .
  8. Start the engine and check for coolant leaks.

Scheme 13

Scheme 13: Engine Coolant Air Bleed Hose Replacement (LUV)
Scheme 13: Engine Coolant Air Bleed Hose Replacement (LUV)
CalloutComponent Name
1Engine Coolant Air Bleed Hose Clamp (Qty: 2) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools .
2Engine Coolant Air Bleed Hose

Engine Coolant Air Bleed Hose Replacement (LUV)

Scheme 14

Scheme 14: Engine Coolant Air Bleed Hose Connector Replacement (LUV)
Scheme 14: Engine Coolant Air Bleed Hose Connector Replacement (LUV)
CalloutComponent Name
1Engine Coolant Air Bleed Hose Refer to Engine Coolant Air Bleed Hose Replacement (LUV) .
2Engine Coolant Air Bleed Hose Connector Retaining Clip
3Engine Coolant Air Bleed Hose Connector

Engine Coolant Air Bleed Hose Connector Replacement (LUV)

  1. Drain the engine coolant system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the following: Engine coolant air bleed hose (1) Engine coolant temperature sensor (2) and connector clip (3) Heated oxygen sensor connector (4)
  3. Remove the heater outlet hose (1) and the heater inlet hose (2).
  4. Remove the water outlet bolts (1) and discard the water outlet seal (2).
  5. Remove the water outlet (3).
  1. Clean the sealing surfaces.
  2. Install the water outlet (3) and a NEW water outlet seal (2).
  3. Install the water outlet bolts (1) and tighten to 8 N.m (71 lb in).
  4. Install the heater outlet hose (1) and the heater inlet hose (2).
  5. Connect the following: Engine coolant temperature sensor (2) and connector clip (3) Heated oxygen sensor connector (4) Engine coolant air bleed hose connector (1)
  6. Fill the engine coolant system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  7. Start the engine and check for coolant leaks.
  1. Drain the engine coolant system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Disconnect the engine coolant temperature sensor connector (1).
  3. Remove the radiator outlet hose connector clip (2) and the radiator outlet hose (3).
  4. Remove the water inlet bolts (1) and discard the water inlet seal (3).
  5. Remove the water inlet (4) and the engine coolant thermostat (2) from the engine.
  1. Clean the sealing surfaces.
  2. Install the water inlet (4) and a NEW water inlet seal (3).
  3. Install the water inlet bolts (1) and tighten to 8 N.m (71 lb in).
  4. Install the radiator outlet hose (3) and retainer clip (2).
  5. Connect the engine coolant temperature connector (1).
  6. Fill the engine coolant system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  7. Start the engine and check for coolant leaks.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  3. Remove the engine coolant temperature sensor connector (1) and the radiator outlet hose (2).
  4. Remove the water inlet pipe mounting fasteners (1).
  5. Remove the water inlet seal (3) and discard.
  6. Remove the thermostat (4).
  1. Clean the sealing surface.
  2. Install the engine thermostat (4) into the water inlet pipe (2) with a NEW seal (3).
  3. Tighten the water inlet pipe mounting fasteners (1) to 9 N.m (80 lb in).
  4. Install the radiator outlet hose (2) to the water inlet pipe.
  5. Connect the engine coolant temperature sensor connector (1).
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  8. After repairs, inspect cooling system for leaks.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-542528-S25099370852013041600000) .
  2. Remove the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
  3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
  4. Loosen the 3 water pump pulley bolts (2) while holding the water pump pulley hub with a wrench.
  5. Remove the 3 water pump pulley bolts (2).
  6. Remove the water pump pulley (1).
  1. Install the water pump pulley (1).
  2. Install the 3 water pump pulley bolts (2).
  3. Tighten the 3 water pump pulley bolts to 22 N.m (16 lb ft) while holding the water pump pulley hub with a wrench.
  4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-542544-S24202329742013041600000) .
  5. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-542544-S10844333092013041600000) .
  6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-542528-S25099370852013041600000) .
  1. Remove the air cleaner housing. Refer to «Air Cleaner Assembly Replacement»(ref-542510-S25363651482013041600000) .
  2. Support the engine with a suitable jack.
  3. Remove the engine mount. Refer to «Engine Mount Replacement»(ref-542468-S12138765342013041600000) .
  4. Raise engine to access the bolts.
  5. Loosen the 3 water pump pulley bolts (1).
  6. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-542468-S29138587992013041600000) .
  7. Remove the 3 water pump pulley bolts (1).
  8. Remove the water pump pulley (2) from the water pump (3).
  1. Install the water pump pulley (2) to the water pump (3).
  2. Install the 3 water pump pulley bolts (1).
  3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-542468-S29138587992013041600000) .
  4. Tighten the 3 water pump pulley bolts (1) to 20 N.m (15 lb ft).
  5. Install the engine mount. Refer to «Engine Mount Replacement»(ref-542468-S12138765342013041600000) .
  6. Install the air cleaner housing. Refer to «Air Cleaner Assembly Replacement»(ref-542510-S25363651482013041600000) .

Scheme 15

Scheme 15: Water Pump Replacement (LUV)
Scheme 15: Water Pump Replacement (LUV)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling . Remove the water inlet. Refer to Water Inlet Replacement (LUW) , Water Inlet Replacement (LUV) . Remove the water pump pulley. Refer to Water Pump Pulley Replacement (LUV) , Water Pump Pulley Replacement (LUW) . Remove the heater outlet hose. Refer to Heater Outlet Hose Replacement (LUV) , Heater Outlet Hose Replacement (LDE, LUW) .
1Water Pump Bolt (Qty: 10) CAUTION: Refer to Fastener Caution . Tighten 8 N.m (71 lb in)
2Water Pump Gasket
3Water Pump Procedure Clean the sealing surfaces. Replace the water pump gasket with a NEW gasket. Remember the location of the short and long bolts when removing.
CAUTION
Refer to Fastener Caution .

Water Pump Replacement (LUV)

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  2. Remove the water pump pulley. Refer to «Water Pump Pulley Replacement (LUV)»(ref-542500-S33570717302013041600000) , «Water Pump Pulley Replacement (LUW)»(ref-542500-S35150273672013041600000) .
  3. Remove the 5 water pump bolts (2).
  4. Remove the water pump (1).
  1. Clean the 5 water pump threads.
  2. Insert a NEW water pump seal ring.
  3. Install the water pump (1).
  4. Install the 5 water pump bolts (2) and tighten to 8 N.m (71 lb in).
  5. Install the water pump pulley. Refer to «Water Pump Pulley Replacement (LUV)»(ref-542500-S33570717302013041600000) , «Water Pump Pulley Replacement (LUW)»(ref-542500-S35150273672013041600000) .
  6. Refill the cooling system. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .

Scheme 16

Scheme 16: Engine Coolant Fan Shroud Replacement (LUV)
Scheme 16: Engine Coolant Fan Shroud Replacement (LUV)
CalloutComponent Name
Preliminary Procedures Drain the engine coolant. Refer to Cooling System Draining and Filling . Remove the radiator surge tank. Refer to Remove the radiator surge tank outlet hose from the engine coolant fan shroud and position it out of the way. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . Remove the front compartment front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement .
1Engine Cooling Fan Shroud Fasteners (Qty: 3) CAUTION: Refer to Fastener Caution .
2Engine Cooling Fan Shroud Assembly. Procedure Disconnect the electrical connectors. Transfer all necessary components.
CAUTION
Refer to Fastener Caution .

Engine Coolant Fan Shroud Replacement (LUV)

Scheme 17

Scheme 17: Engine Coolant Fan Shroud Replacement (LDE LUW)
Scheme 17: Engine Coolant Fan Shroud Replacement (LDE LUW)
CalloutComponent Name
Preliminary Procedure Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement . Unclip transmission cooler lines from shroud if equipped. Unclip radiator surge tank outlet hose from fan shroud. Disconnect any electrical connecters from the fan shroud.
1Engine Coolant Fan Shroud TIP: Unclip engine coolant fan shroud from radiator.

Engine Coolant Fan Shroud Replacement (LDE LUW)

  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .
  2. Remove the front compartment front insulator cover. Refer to «Front Compartment Front Insulator Cover Replacement»(ref-542501-S04169640362013041600000) .
  3. Remove the engine coolant fan shroud. Refer to «Engine Coolant Fan Shroud Replacement (LDE LUW)»(ref-542500-S38607237172013041600000) , «Engine Coolant Fan Shroud Replacement (LUV)»(ref-542500-S18533687162013041600000)
  4. If equipped with an automatic transmission remove the transmission cooler lines. Refer to «Fluid Cooler Inlet Hose Replacement»(ref-542509-S15911944172013041600000) , and «Fluid Cooler Outlet Hose Replacement»(ref-542509-S08037879172013041600000) .
  5. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-542500-S12642615042013041600000) .
  6. Remove the radiator inlet hose from the radiator. Refer to «Radiator Inlet Hose Replacement (LUV)»(ref-542500-S37054095212013041600000) , «Radiator Inlet Hose Replacement (LDE LUW)»(ref-542500-S05451257062013041600000) .
  7. Remove the radiator outlet hose from the radiator. Refer to «Radiator Outlet Hose Replacement (LUV)»(ref-542500-S42141016672013041600000) , «Radiator Outlet Hose Replacement (LDE LUW)»(ref-542500-S32475565962013041600000)
  8. Remove the front bumper fascia assembly. Refer to «Front Bumper Fascia Replacement»(ref-542484-S28756343532013041600000) .
  9. Remove the radiator upper air baffle. Refer to «Radiator Air Baffle Replacement (LUV, LUW)»(ref-542500-S05486226902013041600000)
  10. Remove the three air conditioning condenser bracket fasteners (1) and bracket. (2).
  11. Release the clips securing the air conditioning condenser (1) to the radiator and pull the condenser (1) forward as far as possible.
  12. Support the air conditioning condenser assembly.
  13. Remove the radiator upper bracket fasteners (1) and brackets (2).
  14. Remove the radiator assembly from the vehicle.
  15. Remove the following components from the radiator assembly (1). Radiator upper insulators (2) (Qty:2) Radiator lower insulators (3) (Qty: 2) Radiator temperature sensor (5) and retainer clip (4)
  1. Install the following components to the radiator assembly (1). Radiator upper insulators (2) (Qty:2) Radiator lower insulators (3) (Qty: 2) Radiator temperature sensor (5) and retainer clip (4)
  2. Install the radiator assembly into the vehicle.
  3. Install the radiator upper brackets (2) and bracket fasteners (1) tighten the bracket fasteners to 9Y(80 lb in).
  4. Position the air conditioning condenser (1) to the radiator, and push inward securing the air conditioning condenser to the radiator assembly.
  5. Install the air conditioning condenser bracket (2) and the air conditioning condenser fasteners (1) .
  6. Install the radiator upper air baffle. Refer to «Radiator Air Baffle Replacement (LUV, LUW)»(ref-542500-S05486226902013041600000)
  7. Install the front bumper fascia assembly. Refer to «Front Bumper Fascia Replacement»(ref-542484-S28756343532013041600000) .
  8. Install the radiator outlet hose from the radiator. Refer to «Radiator Outlet Hose Replacement (LUV)»(ref-542500-S42141016672013041600000) , «Radiator Outlet Hose Replacement (LDE LUW)»(ref-542500-S32475565962013041600000)
  9. Install the radiator inlet hose from the radiator. Refer to «Radiator Inlet Hose Replacement (LUV)»(ref-542500-S37054095212013041600000) , «Radiator Inlet Hose Replacement (LDE LUW)»(ref-542500-S05451257062013041600000) .
  10. If equipped with an automatic transmission install the transmission cooler lines. Refer to «Fluid Cooler Inlet Hose Replacement»(ref-542509-S15911944172013041600000) , and «Fluid Cooler Outlet Hose Replacement»(ref-542509-S08037879172013041600000) .
  11. Install the engine coolant fan shroud. Refer to «Engine Coolant Fan Shroud Replacement (LDE LUW)»(ref-542500-S38607237172013041600000) , «Engine Coolant Fan Shroud Replacement (LUV)»(ref-542500-S18533687162013041600000)
  12. Install the front compartment front insulator cover. Refer to «Front Compartment Front Insulator Cover Replacement»(ref-542501-S04169640362013041600000) .
  13. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-542528-S18471970802013041600000) .

Scheme 18

Scheme 18: Radiator Replacement (LDE, LUW)
Scheme 18: Radiator Replacement (LDE, LUW)
CalloutComponent Name
Preliminary Procedures Drain the coolant. Refer to Cooling System Draining and Filling . Remove the engine coolant temperature sensor. Remove the air conditioning condenser. Refer to Air Conditioning Condenser Replacement (LDE,LUW) , Air Conditioning Condenser Replacement (LUV) . Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (LDE LUW) , Engine Coolant Fan Shroud Replacement (LUV) . Remove the radiator hoses. Refer to Radiator Inlet Hose Replacement (LUV) , Radiator Inlet Hose Replacement (LDE LUW) , and Radiator Outlet Hose Replacement (LUV) , Radiator Outlet Hose Replacement (LDE LUW) . Remove the radiator upper bracket. Refer to Radiator Upper Bracket Replacement .
1Radiator TIP: Tilt radiator forward to remove.

Radiator Replacement (LDE LUW)

Scheme 19

Scheme 19: Radiator Air Baffle Replacement (LUV, LUW)
Scheme 19: Radiator Air Baffle Replacement (LUV, LUW)
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia assembly. Refer to Front Bumper Fascia Replacement .
1Radiator Air Upper Baffle Push Pin Retainers (Qty: 4)
2Radiator Air Upper Baffle Assembly

Radiator Air Baffle Replacement (LUV, LUW)

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