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Engine Cooling: Removal & Installation Hummer H3 I

Cooling System (Mechanical) 1 illustration ~1674 words

Removal Procedure

  1. Remove the fan shroud. Refer to «Fan Shroud Replacement (LLR)»(ref-266906-S14900771422007100900000) .
  2. Using J 41240 and J 46406 loosen the fan clutch. See «Special Tools»(ref-266906-S08992574552007100900000) .
  3. Remove the fan hub nut in a counterclockwise rotation.
  4. Remove the cooling fan (2) from the fan clutch. Refer to «Fan Clutch Replacement»(ref-266906-S15326456262007100900000) .

Installation Procedure

  1. Install the cooling fan to the fan clutch. Refer to «Fan Clutch Replacement»(ref-266906-S15326456262007100900000) .
  2. Install the J 46406 and the J 41240 to the fan clutch. See «Special Tools»(ref-266906-S08992574552007100900000) .
  3. Install the fan hub nut to the pulley and hand tighten in a clockwise rotation. Tighten: Tighten the fan clutch nut clockwise to 56 N.m (41 lb ft).
  4. Install the fan shroud. Refer to «Fan Shroud Replacement (LLR)»(ref-266906-S14900771422007100900000) .
  1. Remove the cooling fan. Refer to «Fan Replacement»(ref-266906-S22733303502007100900000) .
  2. Remove the bolts retaining the fan blade to the fan clutch.
  3. Separate the fan blade from the fan clutch.
  1. Assemble the fan to the fan clutch.
  2. Install the 4 bolts to the fan blade and tighten. Tighten: Tighten the bolts to 27 N.m (20 lb ft).
  3. Install the cooling fan. Refer to «Fan Replacement»(ref-266906-S22733303502007100900000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  2. Raise and support the vehicle only high enough to access the thermostat housing (4) through the wheelhouse. Refer to «Lifting and Jacking the Vehicle»(ref-266887-S11959182202007100900000) .
  3. Remove the left wheelhouse liner. Refer to «Wheelhouse Panel Replacement (Front)»(ref-266869-S35383923262007100900000) or «Wheelhouse Panel Replacement (Rear)»(ref-266869-S33735046222007100900000) .
  4. Position the J 38185 to the clamp (3) in order to remove the radiator inlet hose (2) from the thermostat housing (4). See «Special Tools»(ref-266906-S08992574552007100900000) .
  5. Remove the thermostat housing bolts.
  6. Remove the thermostat housing from the engine block.
  7. Clean and inspect the thermostat housing.
  8. Clean and inspect the sealing surface of the engine block.
  1. Position the thermostat housing to the engine block.
  2. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Position the J 38185 to the clamp (3) in order to connect the radiator inlet hose (2) to the thermostat housing (4). See «Special Tools»(ref-266906-S08992574552007100900000) .
  4. Install the left wheelhouse liner. Refer to «Wheelhouse Panel Replacement (Front)»(ref-266869-S35383923262007100900000) or «Wheelhouse Panel Replacement (Rear)»(ref-266869-S33735046222007100900000) .
  5. Lower the vehicle.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  7. Inspect all sealing surfaces for leaks after starting the engine.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  2. Position the J 38185 to the clamp (8) in order to remove the radiator outlet hose (7) from the water outlet housing. See «Special Tools»(ref-266906-S08992574552007100900000) .
  3. Remove the power steering pump bracket. Refer to «Power Steering Pump Bracket Replacement»(ref-266913-S06928910562007100900000) .
  4. Remove the water outlet housing bolts.
  5. Remove the water outlet housing from the cylinder head.
  6. Clean and inspect the water outlet housing.
  7. Clean and inspect the sealing surface of the cylinder head.
  1. Position the water outlet housing to the cylinder head.
  2. Install the water outlet housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the power steering pump bracket. Refer to «Power Steering Pump Bracket Replacement»(ref-266913-S06928910562007100900000) .
  4. Position the J 38185 to the clamp (8) in order to connect the radiator outlet hose (7) to the water outlet housing. See «Special Tools»(ref-266906-S08992574552007100900000) .
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  6. Inspect all sealing surfaces for leaks after starting the engine.
  1. Drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  2. Remove the fan. Refer to «Fan Replacement»(ref-266906-S22733303502007100900000) .
  3. Remove the drive belt. Refer to «Drive Belt Replacement (Without A/C)»(ref-266929-S30060928542007100900000) or «Drive Belt Replacement (With A/C)»(ref-266929-S11799376302007100900000) .
  4. Using the J 46406 , secure the water pump pulley and remove the water pump pulley bolts. See «Special Tools»(ref-266906-S08992574552007100900000) .
  5. Remove the J 46406 .
  6. Remove the water pump pulley.
  7. Remove the water pump bolts.
  8. Remove the water pump.
  9. Clean and inspect the water pump. Refer to «Water Pump Cleaning and Inspection»(ref-266929-S41291847392007100900000) .
  10. Discard the gasket.
  1. Install a new water pump gasket.
  2. Position the water pump to the engine.
  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.
  6. Using the J 46406 , secure the water pump pulley while tightening the water pump pulley bolts. See «Special Tools»(ref-266906-S08992574552007100900000) . Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  7. Remove the J 41240 .
  8. Install the drive belt. Refer to «Drive Belt Replacement (Without A/C)»(ref-266929-S30060928542007100900000) or «Drive Belt Replacement (With A/C)»(ref-266929-S11799376302007100900000) .
  9. Install the fan. Refer to «Fan Replacement»(ref-266906-S22733303502007100900000) .
  10. Fill the cooling system with the specified coolant and concentration. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  11. Inspect for leaks.
  1. Remove the radiator hose-inlet. Refer to «Radiator Inlet Hose Replacement (LLR)»(ref-266906-S20509461402007100900000) .
  2. Remove the transmission oil cooler lines from the fan shroud retainer.
  3. Rotate the slip ring from under the fan shroud.
  4. Disconnect the cam sensor electrical connector.
  5. Remove the fan shroud (3).
  1. Install the fan shroud (3) to the vehicle.
  2. Install the transmission oil cooler lines to the fan shroud retainer.
  3. Rotate the slip ring to the original position.
  4. Connect the cam sensor electrical connector.
  5. Install the radiator hose-inlet. Refer to «Radiator Inlet Hose Replacement (LLR)»(ref-266906-S20509461402007100900000) .
  1. Drain the coolant from the radiator. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  2. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-266877-S05995885982007100900000) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-266887-S11959182202007100900000) .
  4. Remove the oil pan skid plate.
  5. Install the engine shield. Refer to «Engine Shield Replacement»(ref-266869-S08679063702007100900000) .
  6. Remove the transmission cooler lines from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-266879-S35329579762007100900000) for the 4L60-E/4L65-E transmission, if equipped.
  7. Using J 38185 reposition the radiator outlet hose clamp from the radiator. See «Special Tools»(ref-266906-S08992574552007100900000) .
  8. Remove the radiator outlet hose from the radiator.
  9. Lower the vehicle.
  10. Remove the cooling fan. Refer to «Fan Replacement»(ref-266906-S22733303502007100900000) .
  11. Using J 38185 reposition the radiator inlet hose clamp. See «Special Tools»(ref-266906-S08992574552007100900000) .
  12. Remove the radiator inlet hose from the radiator.
  13. Remove the radiator vent inlet hose from the radiator.
  14. Remove the fan shroud from the radiator.
  15. Remove the discharge hose. Refer to «DISCHARGE HOSE REPLACEMENT»(ref-266877-S20236392192007100900000) .
  16. Remove the evaporator tube. Refer to «EVAPORATOR TUBE REPLACEMENT (LEFT HAND DRIVE)»(ref-266877-S00164573142007100900000) or «EVAPORATOR TUBE REPLACEMENT (RIGHT HAND DRIVE)»(ref-266877-S36737363302007100900000) .
  17. Remove the condenser to radiator retaining bolts.
  18. Remove the radiator support bracket retaining bolt.
  19. Remove the radiator support bracket.
  20. Reposition the condenser from the radiator.
  21. Remove the radiator from the vehicle.
  1. Install the radiator assembly to the vehicle.
  2. Reposition the condenser to the radiator.
  3. Install the cooling fan. Refer to «Fan Replacement»(ref-266906-S22733303502007100900000) .
  4. Install the radiator inlet hose to the radiator.
  5. Using J 38185 reposition the radiator inlet hose clamp. See «Special Tools»(ref-266906-S08992574552007100900000) .
  6. Install the radiator support bracket.
  7. Install the radiator support bracket retaining bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  8. Install the condenser to radiator retaining bolts. Tighten: Tighten the bolts to 28 N.m (21 lb ft).
  9. Install the discharge hose. Refer to «DISCHARGE HOSE REPLACEMENT»(ref-266877-S20236392192007100900000) .
  10. Install the evaporator tube. Refer to «EVAPORATOR TUBE REPLACEMENT (LEFT HAND DRIVE)»(ref-266877-S00164573142007100900000) or «EVAPORATOR TUBE REPLACEMENT (RIGHT HAND DRIVE)»(ref-266877-S36737363302007100900000) .
  11. Install the fan shroud to the radiator.
  12. Raise the vehicle.
  13. Install the radiator outlet hose to the radiator.
  14. Using J 38185 reposition the radiator outlet hose clamp to the radiator. See «Special Tools»(ref-266906-S08992574552007100900000) .
  15. Connect the transmission cooler lines to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-266879-S35329579762007100900000) for the 4L60-E/4L65-E transmission, if equipped.
  16. Install the oil pan skid plate.
  17. Install the engine shield. Refer to «Engine Shield Replacement»(ref-266869-S08679063702007100900000) .
  18. Lower the vehicle.
  19. Install the radiator vent inlet hose to the radiator.
  20. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(ref-266877-S05995885982007100900000) .
  21. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .

Scheme 1

Scheme 1: Radiator Air Baffle Assemblies and Deflectors
Scheme 1: Radiator Air Baffle Assemblies and Deflectors
CalloutComponent Name
Preliminary Procedure Remove the grille guard. Refer to Grille Guard/Brush Guard Replacement (Base) or Grille Guard/Brush Guard Replacement (H3X) . Remove the grille. Refer to Grille Replacement .
1Push Pin Retainer
2Radiator Front Baffle Assembly Tip: NOT used on 20U, 22U, 41U, 46U color trucks.
3Push Pin Retainer
4Radiator Front Baffle Assembly

Radiator Air Baffle Assemblies and Deflectors

  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  2. Raise and support the vehicle only high enough to access the coolant heater (6) through the wheelhouse. Refer to «Lifting and Jacking the Vehicle»(ref-266887-S11959182202007100900000) .
  3. Remove the left wheelhouse liner. Refer to «Wheelhouse Panel Replacement (Front)»(ref-266869-S35383923262007100900000) or «Wheelhouse Panel Replacement (Rear)»(ref-266869-S33735046222007100900000) .
  4. Disconnect the coolant heater cord (4) from the coolant heater (6).
  5. Remove the coolant heater from the engine block.
  1. Install the coolant heater into the engine block. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
  2. Connect the coolant heater cord (4) to the coolant heater (6).
  3. Install the left wheelhouse liner. Refer to «Wheelhouse Panel Replacement (Front)»(ref-266869-S35383923262007100900000) or «Wheelhouse Panel Replacement (Rear)»(ref-266869-S33735046222007100900000) .
  4. Lower the vehicle.
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-266906-S16638027172007100900000) or «Cooling System Draining and Filling (Vac-N-Fill)»(ref-266906-S27132971562007100900000) .
  1. Remove the battery box. Refer to «Battery Box Replacement»(ref-266884-S28307291692007100900000) .
  2. Disconnect the coolant heater cord (4) from the coolant heater (6).
  3. Cut the coolant heater cord ties (2, 5) from the following: The battery cables conduit (3) The engine wiring harness conduit (1)
  4. Remove the coolant heater cord (4) from the vehicle.
  1. Position the coolant heater cord (4) to the engine.
  2. Route the coolant heater cord (4) along the engine wiring harness conduit (1) and battery cables conduit (3).
  3. Connect the coolant heater cord (4) to the coolant heater (6).
  4. Secure the coolant heater cord ties (2, 5) to the following: The battery cables conduit (3) The engine wiring harness conduit (1)
  5. Install the battery box. Refer to «Battery Box Replacement»(ref-266884-S28307291692007100900000) .
  6. Place the remaining coolant heater cord (4) between the following: The battery box The underhood fuse block

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