Draining
| WARNING | To avoid personal injury, do not unscrew the coolant pressure relief cap while engine is operating or hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in personal injury. |
| CAUTION | The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be recycled or disposed of correctly. |
Note. About 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.
Scheme 47
- Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise. When the pressure is released, remove the pressure relief cap.
- Place a suitable container below the radiator drain-cock. Open the draincock and allow to drain. Close the radiator draincock when finished.
COOLING SYSTEM FLUSHING
- Drain the cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000)
- Remove the water thermostat. Refer to «THERMOSTAT - 3.0L DURATEC (4V)»(ref-203922-S18635812522005110700000) .
- Install the water hose connection without the water thermostat. NOTE: Refer to the Pro Flush and FILL, Coolant Flush and Fill operating instructions for specific vehicle hook-up.
- Using the special tools, flush the engine and radiator. Use premium cooling system flush.
- Install the water thermostat.
- Backflush the heater core if necessary.
- Fill the cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000)
Scheme 48
Scheme 48: Removal and Installation
- Drain the engine cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000) .
- Remove the degas bottle.
- To install, reverse the removal procedure.
Scheme 49
Scheme 49: Removal and Installation
Scheme 50
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Scheme 56
- Drain the engine cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000) .
- Raise and support the vehicle. .
- Remove the lower splash shields.
- Disconnect the lower radiator hose, the high pressure transaxle line and the degas return hose.
- Lower the vehicle.
- Disconnect the transaxle return line.
- Disconnect the upper radiator hose and degas return hose.
- Position the hood latch assembly out of the way.
- Remove the two bolts and the center support.
- Remove the two top bolts retaining the cooling fan to the radiator.
- Remove the upper radiator support brackets, and remove the radiator from the vehicle.
- To install, reverse the removal procedure.
Scheme 57
Scheme 57: Removal and Installation
Scheme 58
Scheme 59
- Drain the engine Cooling System. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000) .
- Remove the air cleaner outlet tube.
- Disconnect the five hoses from the thermostat housing and remove the thermostat housing.
- Disconnect the engine coolant temperature (ECT) sensor from the bypass tube.
- Remove the bolt, stud, and the water bypass tube. NOTE: Clean and inspect the sealing surfaces.
- To install, reverse the removal procedure.
Scheme 60
Scheme 60: Removal and Installation
Scheme 61
- Drain the engine cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000)
- Separate the thermostat housing.
- Remove the thermostat and the O-ring seal from the thermostat housing. NOTE: Clean and inspect the sealing surfaces.
- To install reverse the removal procedure.
Scheme 62
Scheme 62: Removal and Installation
Scheme 63
Scheme 64
- Drain the engine cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000) .
- Remove the air cleaner outlet tube.
- Remove the water pump belt tensioner, if equipped. Refer to «BELT TENSIONER - WATER PUMP»(ref-175803-S08722112132005042900000) .
- Disconnect the three hoses.
- Remove the bolts and the water pump assembly.
- Separate the water pump from the water pump housing. NOTE: Clean and inspect the sealing surfaces.
- To install, reverse the removal procedure.
Scheme 65
Scheme 65: Removal and Installation
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Scheme 71
- Disconnect the battery ground cable.
- Position the hood latch out of the way.
- If equipped, remove the upper radiator tie strap.
- Raise and support the vehicle.
- Remove the lower center support bolt and the lower fan bolts.
- Lower the vehicle.
- Remove the upper center support bolt and the upper center support.
- Disconnect the LH fan electrical connector.
- Remove the LH and RH upper radiator supports.
- Tilt the radiator forward for clearance.
- Remove the five bolts and the LH cooling fan.
- If necessary remove the bolt and disconnect the electrical connector, remove the RH fan.
- To install, reverse the removal procedure.
Scheme 72
Scheme 72: CYLINDER BLOCK - CORE PLUG REPLACEMENT
- Use a slide hammer or tools suitable to remove the cylinder block core plug.
- Inspect the cylinder block plug bore for any damage that would, interfere with the correct sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug.
- Coat the cylinder block core plug and bore lightly with Threadlock 262 and install the cylinder block core plug.
Scheme 73
| CAUTION | Use care during this procedure so as not to disturb or distort the cup sealing surface. |
| CAUTION | When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. |
- Use a tool suitable to seat the cup-type cylinder block core plug.
Scheme 74
Scheme 74: Expansion-Type
| CAUTION | Do not contact the crown when installing an expansion-type cylinder block core plug. This could expand the plug before seating and result in leakage. |
- Use tool suitable to seat the expansion-type cylinder block core plug.
Scheme 75
Scheme 75: Removal and Installation
Scheme 76
- Drain the cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-203922-S20262522882005110700000) .
- Raise the vehicle.
- Disconnect the block heater power cable from the block heater. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal.
- Remove the block heater. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or damage to the cable may occur.
- To install, reverse the removal procedure.