Engine Cooling System: Removal & Installation Chevrolet Spark M300

Removal Procedure

1. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
2. Loosen the radiator surge tank outlet hose clamp (3) and remove the radiator surge tank outlet hose from the radiator surge tank.
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
4. Remove the intake manifold support bracket bolts (2, 3).
5. Remove the intake manifold support bracket (1).
6. Loosen the radiator surge tank outlet hose clamp (1) and remove the radiator surge tank outlet hose from the water pump.
7. Transfer parts as necessary.

Installation Procedure

1. Install the radiator surge tank outlet hose with the radiator surge tank outlet hose clamp (1) to the water pump.
2. Install the intake manifold support bracket (1).
3. Install the intake manifold support bracket bolts (2) and tighten to 22 (16 lb ft).
4. Install the intake manifold support bracket bolt (3) and tighten to 58 (42 lb ft).
5. Lower the vehicle.
6. Install the radiator surge tank outlet hose with the radiator surge tank outlet hose clamp (3) to the radiator surge tank.
7. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
8. Start the engine and check for coolant leaks.

Scheme 3

Radiator Inlet Hose Replacement

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
3. Loosen the radiator outlet hose clamp (1).
4. Remove the radiator outlet hose from the radiator.
5. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
7. Loosen the radiator outlet hose clamp (1).
8. Remove the radiator outlet hose from the water pump outlet pipe.

1. Install the radiator outlet hose to the water pump outlet pipe.
2. Install the radiator outlet hose clamp (1).
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
5. Install the radiator outlet hose to the radiator.
6. Install the radiator outlet hose clamp (1).
7. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .

Scheme 4

Engine Coolant Outlet Pipe Replacement

1. Drain the system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
3. Disconnect the heater inlet hose and clamp (1).
4. Disconnect the coolant hose and clamp (2).
5. Disconnect the radiator inlet hose and clamp (3).
6. Remove the engine coolant thermostat (2). Refer to «Engine Coolant Thermostat Replacement»(ref-544478-S39979168742013042400000) .
7. Remove the engine coolant thermostat housing bolts (1).
8. Remove the engine coolant thermostat housing (2).

1. Install the coolant thermostat housing (2).
2. Install the engine coolant thermostat housing bolts (1) and tighten to 25 (18 lb ft).
3. Install the engine coolant thermostat (2). Refer to «Engine Coolant Thermostat Replacement»(ref-544478-S39979168742013042400000) .
4. Connect the radiator inlet hose and clamp (3).
5. Connect the coolant hose and clamp (2).
6. Connect the heater inlet hose and clamp (1).
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
9. Start the engine and check for coolant leaks.

1. Open the hood.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-544482-S31138545022013042400000) .
3. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
4. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
5. Disconnect the radiator inlet hose and clamp (3).
6. Disconnect the electrical connector from the engine coolant thermostat heater connector.
7. Remove the engine coolant thermostat bolts (1).
8. Remove the engine coolant thermostat assembly (2).

1. Install the engine coolant thermostat assembly (2).
2. Install the 3 engine coolant thermostat bolts (1) and tighten to 10 (89 lb in).
3. Connect the electrical connector to the engine coolant thermostat heater connector.
4. Connect the radiator inlet hose and clamp (3).
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
6. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-544482-S31138545022013042400000) .
8. Start the engine and check for coolant leaks.
9. Close the hood.

1. Drain the coolant. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
2. Remove the water pump and generator belt. Refer to «Water Pump and Generator Belt Replacement»(ref-544511-S22475798062013042400000) .
3. Remove the generator. Refer to «Generator Replacement»(ref-544482-S14779421592013042400000) .
4. Remove the intake manifold support bracket bolts (2, 3).
5. Remove the intake manifold support bracket (1).
6. Disconnect the radiator surge tank outlet hose and clamp (1).
7. Disconnect the heater outlet hose and clamp (2).
8. Disconnect the water pipe hose and clamp (3).
9. Remove the 4 water pump bolts (1).
10. Remove the water pump assembly (2) from the engine block.
11. Remove the water pump oil seal ring.

1. Clean the water pump threads.
2. Insert a NEW water pump seal ring.
3. Install the water pump assembly (2) to engine block.
4. Install the 4 water pump bolts (1) and tighten to 10 (89 lb in).
5. Connect the water pipe hose and clamp (3).
6. Connect the heater outlet hose and clamp (2).
7. Connect the radiator surge tank outlet hose and clamp (1).
8. Install the intake manifold support bracket (1).
9. Install the intake manifold support bracket bolts (2) and tighten to 25 (18 lb ft).
10. Install the intake manifold support bracket bolt (3) and tighten to 46 (34 lb ft).
11. Install the generator. Refer to «Generator Replacement»(ref-544482-S14779421592013042400000) .
12. Install the water pump and generator belt. Refer to «Water Pump and Generator Belt Replacement»(ref-544511-S22475798062013042400000) .
13. Fill the engine cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
14. Start the engine and check for coolant leaks.

Scheme 5

Engine Coolant Fan Shroud Replacement

1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-544523-S17935609682013042400000) .
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-544482-S31138545022013042400000) .
4. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
5. Disconnect the radiator inlet hose from the radiator. Refer to «Radiator Inlet Hose Replacement»(ref-544478-S31129830872013042400000) .
6. Disconnect the radiator outlet hose from the radiator. Refer to «Radiator Outlet Hose Replacement»(ref-544478-S25085264272013042400000) .
7. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-544493-S26050861272013042400000) .
8. Remove the front bumper fascia. Refer to «Front Bumper Fascia Replacement»(ref-544457-S12072716012013042400000) .
9. Remove the 3 right side opening cover retainer (1) and right side opening cover (2).
10. Remove the 4 left side opening cover retainer (3) and left side opening cover (4).
11. Remove the 4 upper opening cover retainer (1) and upper opening cover (2).
12. Remove air conditioning compressor and condenser upper pipe nut (1).
13. Remove air conditioning compressor and condenser under pipe nut (2).
14. Remove air conditioning compressor and condenser pipe from the air conditioning condenser.
15. Remove the 2 radiator support bracket bolts (1).
16. Remove the 2 radiator support brackets (2).
17. Disconnect electrical connectors from the fan shroud.
18. Remove the radiator and air conditioning condenser and engine coolant fan shroud from the vehicle.
19. Unclip engine coolant fan shroud (1) from the radiator (3).
20. Unclip conditioning condenser (2) from the radiator (3).
21. Transfer parts as needed.

1. Clip the engine coolant fan shroud (1) to the radiator (3).
2. Clip the air conditioning condenser (2) to the radiator (3).
3. Install the radiator and air conditioning condenser and engine coolant fan shroud to the vehicle.
4. Install the 2 radiator support bracket (2).
5. Install the 2 radiator support bracket bolt (1) and tighten to 22 (16 lb in).
6. Connect electrical connectors from the fan shroud.
7. Install air conditioning compressor and condenser pipe to the air conditioning condenser.
8. Install air conditioning compressor and condenser upper pipe nut (1) and tighten to 11 (96 lb in).
9. Install air conditioning compressor and condenser under pipe nut (2) and tighten to 11 (96 lb in).
10. Install the upper opening cover (2) and 4 upper opening cover retainer (1).
11. Install the left side opening cover (4) and 4 left side opening cover retainer (3).
12. Install the right side opening cover (2) and 3 right side opening cover retainer (1).
13. Install the front bumper fascia. Refer to «Front Bumper Fascia Replacement»(ref-544457-S12072716012013042400000) .
14. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-544493-S26050861272013042400000) .
15. Connect the radiator outlet hose to the radiator. Refer to «Radiator Outlet Hose Replacement»(ref-544478-S25085264272013042400000) .
16. Connect the radiator inlet hose to the radiator. Refer to «Radiator Inlet Hose Replacement»(ref-544478-S31129830872013042400000) .
17. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-544476-S34003319142013042400000) .
18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-544482-S31138545022013042400000) .
19. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-544478-S02274412632013042400000) .
20. Charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-544523-S17935609682013042400000) .
21. Start the engine and check for coolant leaks.

1. Remove the front bumper fascia. Refer to «Front Bumper Fascia Replacement»(ref-544457-S12072716012013042400000) .
2. Remove the 3 right side opening cover retainer (1) and right side opening cover (2).
3. Remove the 4 left side opening cover retainer (3) and left side opening cover (4).
4. Remove the 4 upper opening cover retainer (1) and upper opening cover (2).
5. Remove the 2 radiator support bracket bolt (1).
6. Remove the 2 radiator support bracket (2).

1. Install the 2 radiator support bracket (2).
2. Install the 2 radiator support bracket bolts (1) and tighten to 22 (16 lb in).
3. Install the upper opening cover (2) and 4 upper opening cover retainers (1).
4. Install the left side opening cover (4) and 4 left side opening cover retainers (3).
5. Install the right side opening cover (2) and 3 right side opening cover retainers (1).
6. Install the front bumper fascia. Refer to «Front Bumper Fascia Replacement»(ref-544457-S12072716012013042400000) .

Scheme 6

Radiator Support Replacement