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Engine Cooling System: Removal & Installation Chevrolet Volt I

Cooling System (Mechanical) 9 illustrations ~1367 words

Removal Procedure

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000)
  2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-487468-S35284396212012072300000)
  3. Remove the radiator inlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  4. Remove the radiator inlet hose (2) from the engine.
  5. Remove the radiator inlet hose clamp (1) at radiator using BO-38185 Hose Clamp Pliers.
  6. Remove the radiator inlet hose (2) from the radiator.
  7. 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 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 engine using BO-38185 Hose Clamp Pliers.
  6. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-487468-S35284396212012072300000)
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000)
  1. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-487468-S35284396212012072300000)
  2. Remove the heater coolant heater air supply hose from the radiator outlet front hose. Refer to «Heater Coolant Heater Air Supply Hose Replacement»(ref-487454-S35811763702012072300000)
  3. Disconnect the radiator outlet front hose quick connect (1) at engine.
  4. Remove the radiator outlet front hose (2) from the engine.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-487431-S15227705202012072300000)
  6. Remove the radiator outlet front hose clamp (1) at radiator using BO-38185 Hose Clamp Pliers.
  7. Remove the radiator outlet front hose (2) from the radiator.
  8. Remove the radiator outlet front hose from the vehicle.
  1. Install the radiator outlet front hose to the vehicle.
  2. Install the radiator outlet front hose (2) to the radiator.
  3. Install the radiator outlet front hose clamp (1) at radiator using BO-38185 Hose Clamp Pliers.
  4. Install the radiator outlet front hose (2) to the engine.
  5. Connect the radiator outlet front hose quick connect (1) at engine.
  6. Lower the vehicle.
  7. Install the heater coolant heater air supply hose to the radiator outlet front hose. Refer to «Heater Coolant Heater Air Supply Hose Replacement»(ref-487454-S35811763702012072300000)
  8. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-487468-S35284396212012072300000)
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000)

Scheme 3

Scheme 3: Radiator Upper Bracket Replacement
Scheme 3: Radiator Upper Bracket Replacement
CalloutComponent Name
Preliminary Procedure Remove front compartment front sight shield. Refer to Front Compartment Front Sight Shield Replacement
1Radiator Upper Bracket Bolt (Qty 2) CAUTION: Refer to Fastener Caution . Tighten 22 N.m (16 lb ft)
2Radiator Upper Bracket (Qty 2)
CAUTION
Refer to Fastener Caution .

Radiator Upper Bracket Replacement

Scheme 4

Scheme 4: Cooling Fan and Shroud Replacement
Scheme 4: Cooling Fan and Shroud Replacement
CalloutComponent Name
Preliminary Procedure Remove the drive motor battery radiator surge tank. Refer to Drive Motor Battery Radiator Surge Tank Replacement Remove the drive motor battery coolant pump. Refer to Drive Motor Battery Coolant Pump Replacement Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement Remove the radiator outlet front hose. Refer to Radiator Outlet Front Hose Replacement Disconnect the electrical connector from the coolant fans. Disconnect all wire retainers from shroud.
1Cooling Fan and Shroud Bolts (Qty: 2). CAUTION: Refer to Fastener Caution . Tighten 5 N.m (44 lb in)
2Cooling Fan and Shroud
CAUTION
Refer to Fastener Caution .

Cooling Fan and Shroud Replacement

Scheme 5

Scheme 5: Engine Coolant Air Bleed Hose Connector Replacement
Scheme 5: Engine Coolant Air Bleed Hose Connector Replacement
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling . Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Engine Coolant Air Bleed Hose Clamps (Qty: 2) Procedure Reposition the engine coolant air bleed hose clamps using BO 38185 Hose Clamp Pliers Special Tools BO 38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools
2Retainer Clips (Qty: 2)
3Engine Coolant Air Bleed Hose NOTE: Replace corroded hose clamps and brackets.
NOTE
Replace corroded hose clamps and brackets.

Engine Coolant Air Bleed Hose Connector Replacement

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000) .
  2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-487468-S35284396212012072300000) .
  3. Disconnect the engine coolant temperature sensor (ECT) connector (1).
  4. Disconnect the radiator inlet hose (1), the engine coolant air bleed hose (2) and the heater outlet hose (3), from the water outlet.
  5. Remove the 4 water outlet bolts (1).
  6. Remove the water outlet (3) and DISCARD the seal (2).
  1. Position the water outlet (3) and a NEW seal (2), to the cylinder head.
  2. Install the 4 water outlet bolts (1) and tighten to 8 N.m (71 lb in).
  3. Connect the radiator inlet hose (1), the engine coolant air bleed hose (2) and the heater outlet hose (3), to the water outlet.
  4. Install the engine coolant temperature sensor (1) and the battery positive cable (3), to the A/C compressor hose (2).
  5. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-487468-S35284396212012072300000) .
  6. Fill the radiator coolant system. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000) .
  7. Start the engine and check for coolant leaks.
  1. Drain coolant fluid. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-487468-S10857515562012072300000) .
  3. Remove the radiator inlet hose (2) and disconnect the engine coolant temperature sensor connector (1), from the water inlet pipe (3).
  4. Remove the water inlet pipe bolts (1).
  5. Inspect the seal (2) and replace as necessary.
  1. Clean the sealing surfaces.
  2. Install the water inlet pipe (3) and seal (2).
  3. Tighten the water inlet pipe bolts (1) to 8 N.m (71 lb in).
  4. Connect the engine coolant temperature sensor (1) and the radiator inlet hose (2).
  5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-487468-S10857515562012072300000) .
  6. Fill up the coolant fluid. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000) .
  7. Start the engine and check for coolant leaks.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-487468-S10857515562012072300000) .
  2. Remove the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-487432-S38211323962012072300000) .
  3. Remove the water pump belt. Refer to «Water Pump Belt Replacement»(ref-487508-S13866772582012072300000) .
  4. Loosen the 3 water pump pulley bolts (2) while holding up the water pump pulley hub with a spanner.
  5. Remove the 3 water pump pulley bolts.
  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 10 N.m (89 lb in) while holding up the water pump pulley hub with a spanner.
  4. Install the water pump belt. Refer to «Water Pump Belt Replacement»(ref-487508-S13866772582012072300000) .
  5. Install the engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right Side»(ref-487432-S38211323962012072300000) .
  6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-487468-S10857515562012072300000) .
  7. Close hood.
  1. Remove the air cleaner assembly (1). Refer to «Air Cleaner Assembly Replacement»(ref-487468-S10857515562012072300000)
  2. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-487432-S22693934172012072300000)
  3. Remove the right engine mount (1). Refer to «Engine Mount Replacement - Right Side»(ref-487432-S00515192282012072300000)
  4. Remove the right engine mount bracket (1). Refer to «Engine Mount Bracket Replacement - Right Side»(ref-487432-S38211323962012072300000)
  5. Cut the water pump belt (1) with a appropriate cutting tool as shown.
  6. Remove and discard the water pump belt.
  1. Position a NEW water pump belt (1) on the crankshaft pulley and water pump pulley (2) as shown.
  2. Using a socket and ratchet on the crankshaft pulley bolt, rotate the crankshaft in the direction of the arrow until the belt is fully installed on the water pump pulley.
  3. After the belt is on the water pump pulley, rotate the crankshaft an additional complete revolution and ensure the water pump belt is fully seated on the crankshaft and water pump pulleys.
  4. Install the right engine mount bracket (1). Refer to «Engine Mount Bracket Replacement - Right Side»(ref-487432-S38211323962012072300000) .
  5. Install the right engine mount (1). Refer to «Engine Mount Replacement - Right Side»(ref-487432-S00515192282012072300000) .
  6. Remove the engine support fixture.
  7. Install the air cleaner assembly (1). Refer to «Air Cleaner Assembly Replacement»(ref-487468-S10857515562012072300000)
  1. Drain coolant fluid. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000) .
  2. Remove the water pump pulley. Refer to «Water Pump Pulley Replacement»(ref-487508-S23042635922012072300000) .
  3. Remove the radiator inlet hose (2) and the engine coolant temperature sensor connector (1), from the water inlet pipe (3).
  4. Remove the heater water shutoff hose (1).
  5. Remove the 5 short water pump bolts (2) and the 5 long water pump bolts (1).
  6. Remove the water pump (4).
  7. Remove the water pump gasket (3).
  8. If replacing the water pump, transfer the water inlet pipe and the thermostat to the new water pump. Refer to «Water Inlet Replacement»(ref-487508-S24533321852012072300000) .
  1. Clean the sealing surfaces.
  2. The water pump and engine front cover bolts are located as followed: Engine front cover special bolts without cone end 60 mm (2.362 in) (1). Engine front cover standard bolts with cone end 52 mm (2.047 in) (2). Water pump bolts 25 mm (0.984 in) (3).
  3. Install the water pump (4) and a NEW water pump gasket (3).
  4. Install the 5 water pump bolts (2) and the 5 engine front cover (1) and tighten in a cross sequence to 8 N.m (71 lb in).
  5. Install the water pump pulley. Refer to «Water Pump Pulley Replacement»(ref-487508-S23042635922012072300000) .
  6. Install the heater water shutoff hose (1).
  7. Install the radiator inlet hose (2) and the engine coolant temperature sensor connector (1), to the water inlet pipe (3).
  8. Fill up the coolant fluid. Refer to «Cooling System Draining and Filling»(ref-487508-S37661417372012072300000) .
  9. Start the engine and check for coolant leaks.

Scheme 6

Scheme 6: Engine Coolant Temperature Sensor Replacement
Scheme 6: Engine Coolant Temperature Sensor Replacement
CalloutComponent Name
Preliminary Procedure Drain the coolant. Refer to Cooling System Draining and Filling Remove the front wheelhouse front liner on the passenger side. Refer to Front Wheelhouse Front Liner Replacement Disconnect the electrical connector from the coolant temperature sensor.
1Engine Coolant Temperature Sensor Retaining Clip.
2Engine Coolant Temperature Sensor

Engine Coolant Temperature Sensor Replacement

Scheme 7

Scheme 7: Radiator Replacement
Scheme 7: Radiator Replacement
CalloutComponent Name
Preliminary Procedure Drain the coolant. Refer to Cooling System Draining and Filling Remove cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement Remove transmission fluid auxiliary cooler. Refer to Transmission Fluid Auxiliary Cooler Replacement Disconnect the drive motor battery coolant/air separator from the radiator. Refer to Drive Motor Battery Coolant/Air Separator Replacement Disconnect the heater vent hose from the radiator. Refer to Heater Vent Hose Replacement Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement Remove radiator outlet front hose. Refer to Radiator Outlet Front Hose Replacement Disconnect the electrical connector from the engine coolant temperature sensor.
1Radiator

Radiator Replacement

Scheme 8

Scheme 8: Radiator Air Lower Baffle and Deflector Replacement
Scheme 8: Radiator Air Lower Baffle and Deflector Replacement
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation
1Radiator Air Lower Baffel and Deflector Retainers (Qty 3)
2Radiator Air Lower Baffel and Deflector

Radiator Air Lower Baffle and Deflector Replacement

Scheme 9

Scheme 9: Radiator Air Side Baffle Replacement - Left Side
Scheme 9: Radiator Air Side Baffle Replacement - Left Side
CalloutComponent Name
Preliminary Procedure Remove front bumper fascia. Refer to Front Bumper Fascia Removal and Installation
1Radiator Air Side Baffel Retainers (Qty 5)
2Radiator Air Side Baffel

Radiator Air Side Baffle Replacement - Left Side

Scheme 10

Scheme 10: Radiator Air Side Baffle Replacement - Right Side
Scheme 10: Radiator Air Side Baffle Replacement - Right Side
CalloutComponent Name
Preliminary Procedure Remove front bumper fascia. Refer to Front Bumper Fascia Removal and Installation Remove the ambient air temperature sensor. Refer to Ambient Air Temperature Sensor Replacement
1Radiator Air Side Baffel Retainers (Qty 6)
2Radiator Air Side Baffel

Radiator Air Side Baffle Replacement - Right Side

Scheme 11

Scheme 11: Radiator Air Seal Replacement
Scheme 11: Radiator Air Seal Replacement
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia center support bracket. Refer to Front Bumper Fascia Center Support Bracket Replacement
1Radiator Air Seal Retainers (Qty 5)
2Radiator Air Seal Procedure Unclip the drive motor power inverter module cooling inlet hose. Unclip hose retainer from the radiator air seal.

Radiator Air Seal Replacement

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