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Engine Cooling System: Removal & Installation Pontiac Aztek I

Cooling System (Mechanical) 43 illustrations ~2084 words

Removal Procedure

  1. Reposition the reservoir hose clamp at the radiator overflow fitting using the J 38185.
  2. Remove the reservoir hose at the radiator overflow fitting.
  3. Remove the reservoir mounting clip.
  4. Remove the coolant reservoir.

Scheme 25

Scheme 25
Scheme 25

Installation Procedure

  1. Install the coolant reservoir.
  2. Install the reservoir mounting clip.
  3. Connect the reservoir hose to the radiator overflow fitting.
  4. Reposition the reservoir hose clamp to secure the hose using the J 38185.
  5. Fill the coolant reservoir. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .

Scheme 26

Scheme 26
Scheme 26
  1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  2. Reposition the hose clamp at the radiator using the J 38185.
  3. Disconnect the radiator inlet hose from the radiator.
  4. Reposition the hose clamp at the thermostat housing using the J 38185.
  5. Disconnect the radiator inlet hose from the thermostat housing.
  6. Remove the radiator inlet hose.

Scheme 27

Scheme 27
Scheme 27
  1. Install the radiator inlet hose.
  2. Connect the radiator inlet hose to the radiator.
  3. Reposition the hose clamp at the radiator to secure the hose using the J 38185.
  4. Connect the radiator inlet hose to the thermostat housing.
  5. Reposition the hose clamp at the thermostat housing to secure the hose using the J 38185.
  6. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .

Scheme 28

Scheme 28
Scheme 28
  1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  2. Reposition the hose clamp at the water pump housing using the J 38185.
  3. Disconnect the radiator outlet hose from the water pump housing.
  4. Reposition the hose clamp at the radiator using the J 38185.
  5. Disconnect the radiator outlet hose from the radiator.
  6. Remove the radiator outlet hose.

Scheme 29

Scheme 29
Scheme 29
  1. Install the radiator outlet hose.
  2. Connect the radiator outlet hose to the radiator.
  3. Reposition the hose clamp at the radiator to secure the hose using the J 38185.
  4. Connect the radiator outlet hose to the water pump housing.
  5. Reposition the hose clamp at the water pump housing to secure the hose using the J 38185.
  6. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .

Scheme 30

Scheme 30
Scheme 30
  1. Remove the air cleaner duct.
  2. Remove the throttle cable bracket in order to gain access to the throttle body heater hose clamp.
  3. Drain the coolant until the coolant level is below the throttle body heater hoses. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  4. Use the J 38185 in order to remove the hose clamp.
  5. Remove the throttle body heater inlet hose.

Scheme 31

Scheme 31
Scheme 31
  1. Install the throttle body heater inlet hose.
  2. Use the J 38185 in order to install the hose clamps.
  3. Install the throttle cable bracket.
  4. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  5. Install the air cleaner duct.

Scheme 32

Scheme 32
Scheme 32
  1. Remove the air cleaner duct.
  2. Drain the coolant until the coolant level is below the throttle body heater hoses. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  3. Use the J 38185 in order to remove the hose clamp.
  4. Remove the throttle body heater outlet hose.

Scheme 33

Scheme 33
Scheme 33
  1. Install the throttle body heater outlet hose.
  2. Use the J 38185 in order to install the hose clamps.
  3. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  4. Install the air cleaner duct.

Scheme 34

Scheme 34
Scheme 34
CAUTIONAn electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.
CAUTIONTo help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan blades.

  1. Turn the ignition off.
  2. Remove the cooling fans with the cooling fan shroud. Refer to «COOLING FAN REPLACEMENT - ELECTRIC»(ref-203946-S16456024852005072900000) . Important: Turn the cooling fan nut clockwise to loosen.
  3. Remove the cooling fan nut.
  4. Remove the cooling fan.

Scheme 35

Scheme 35
Scheme 35
  1. Install the cooling fan. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices. Important: Turn the cooling fan nut counterclockwise to tighten.
  2. Install the cooling fan nut. Tighten Tighten the nut to 6 N.m (53 lb. in).
  3. Install the cooling fans with the cooling fan shroud. Refer to «COOLING FAN REPLACEMENT - ELECTRIC»(ref-203946-S16456024852005072900000) .

Scheme 36

Scheme 36
Scheme 36
CAUTIONAn electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.
CAUTIONTo help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39
  1. Remove the air cleaner and duct assembly. Refer to in Engine Controls - 3.4L.
  2. Remove the cooling fan harness electrical connector.
  3. Remove right side diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL - RIGHT in Body Front End.
  4. Loosen the engine mount strut nuts.
  5. Remove the engine mount strut bracket brace bolts from the upper radiator support and rotate the struts and brackets rearward.
  6. Remove upper radiator hose. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-203946-S31176646802005072900000)
  7. Remove the radiator upper mount bolts (1).
  8. Remove the radiator upper mounts.
  9. Remove the cooling fan shroud bolts.
  10. Reposition the coolant overflow hose clamp at the radiator using the J 38185.
  11. Disconnect and reposition the coolant overflow hose.
  12. Disconnect the upper TOC line from the radiator. Refer to TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING in Automatic Transaxle - 4T65-E.
  13. Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  14. Disconnect the TOC lines from the fan module retainer clip.
  15. Lower the vehicle.
  16. Disconnect the engine wiring harness retainers at the engine harness bracket.
  17. Reposition the engine wiring harness.
  18. Remove the cooling fans with the cooling fan shroud.

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41: Installation Procedure
Scheme 41: Installation Procedure

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43
  1. Install the cooling fans with the cooling fan shroud.
  2. Reposition the engine wiring harness.
  3. Connect the engine wiring harness retainers at the engine harness bracket.
  4. Raise the vehicle.
  5. Connect the TOC lines to the fan module retainer clip.
  6. Lower the vehicle.
  7. Connect the upper TOC line to the radiator. Refer to TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING in Automatic Transaxle - 4T65-E. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  8. Install the cooling fan shroud bolts. Tighten Tighten the bolts to 6 N.m (53 lb. in).
  9. Install the radiator upper mounts.
  10. Install the radiator upper mount bolts (1). Tighten Tighten the bolts to 10 N.m (88 lb. in).
  11. Install the coolant overflow hose to the radiator.
  12. Reposition the hose clamp to secure the coolant overflow hose using the J 38185.
  13. Install the upper radiator hose. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-203946-S31176646802005072900000) .
  14. Position the engine mount struts brackets flush with the upper radiator support.
  15. Install the engine mount strut bracket brace bolts to the upper radiator support. Tighten Tighten bolts to 28 N.m (21 lb ft).
  16. Tighten the engine mount strut nuts. Tighten Tighten the nuts to 48 N.m (35 lb ft).
  17. Install right side diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL - RIGHT in Body Front End.
  18. Install the cooling fan harness electrical connector.
  19. Install the air cleaner and duct assembly.

Scheme 44

Scheme 44
Scheme 44
CAUTIONAn electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.
CAUTIONTo help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan blades.

Scheme 45

Scheme 45
Scheme 45
  1. Turn the ignition off.
  2. Remove the cooling fan and shroud assembly. Refer to «COOLING FAN REPLACEMENT - ELECTRIC»(ref-203946-S16456024852005072900000) . Important: Turn the cooling fan nut clockwise to loosen.
  3. Remove the cooling fan nut.
  4. Remove the cooling fan from the shroud.
  5. Disconnect the electrical connector from the cooling fan motor.
  6. Remove the screws from the cooling fan motor.
  7. Remove the cooling fan motor.

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47: Installation Procedure
Scheme 47: Installation Procedure
  1. Install the cooling fan motor. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  2. Install the screws to the cooling fan motor. Tighten Tighten the screws to 6 N.m (53 lb. in).
  3. Connect the electrical connector to the cooling fan motor.
  4. Install the cooling fan to the shroud. Important: Turn the cooling fan nut counterclockwise to tighten.
  5. Install the cooling fan nut. Tighten Tighten the nut to 6 N.m (53 lb. in).
  6. Install the cooling fan and shroud assembly. Refer to «COOLING FAN REPLACEMENT - ELECTRIC»(ref-203946-S16456024852005072900000) .

Scheme 48

Scheme 48
Scheme 48
CAUTIONAn electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.
CAUTIONTo help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan blades.

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50
  1. Remove the cooling fan assembly including the shroud. Refer to «COOLING FAN REPLACEMENT - ELECTRIC»(ref-203946-S16456024852005072900000) . Important: Turn the cooling fan nuts clockwise to loosen.
  2. Remove the cooling fan nuts.
  3. Remove the cooling fans from the shroud.
  4. Disconnect the fan motor electrical connectors.
  5. Remove the fan motor screws.
  6. Remove the fan motors from the cooling fan shroud.
  7. Remove the heat shields from the cooling fan shroud.

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52: Installation Procedure
Scheme 52: Installation Procedure

Scheme 53

Scheme 53
Scheme 53
  1. Install the heat shields to the cooling fan shroud.
  2. Install the fan motors to the cooling fan shroud. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  3. Install the screws to the cooling fan motor. Tighten Tighten the screws to 6 N.m (53 lb. in).
  4. Connect the cooling fan motor electrical connectors.
  5. Install the cooling fans to the shroud. Important: Turn the cooling fan nuts counterclockwise to tighten.
  6. Install the cooling fan nuts. Tighten Tighten the nuts to 6 N.m (53 lb. in).
  7. Install the cooling fan assembly including the shroud. Refer to «COOLING FAN REPLACEMENT - ELECTRIC»(ref-203946-S16456024852005072900000) .

Scheme 54

Scheme 54
Scheme 54
  1. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  2. Remove the air baffle bolts.
  3. Remove the air baffle.

Scheme 55

Scheme 55
Scheme 55
  1. Install the air baffle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  2. Install the air baffle bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft).
  3. Lower the vehicle.

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57: Removal Procedure
Scheme 57: Removal Procedure
  1. Drain the engine cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  2. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  3. Remove the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  4. Remove the right engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
  5. Remove the engine coolant heater cord from the engine coolant heater.
  6. Loosen the coolant heater bolt.
  7. Remove the coolant heater.

Scheme 58

Scheme 58
Scheme 58

Scheme 59

Scheme 59: Installation Procedure
Scheme 59: Installation Procedure

Scheme 60

Scheme 60
Scheme 60
  1. Apply GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the coolant heater seal and the coolant heater hole.
  2. Ensure that the coolant heater element is horizontal and pointed toward the front of the engine. The 3 o'clock position (2) is DESIRED. The 2 o'clock position (1) and the 4 o'clock position (3) are acceptable.
  3. Install the coolant heater. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  4. Install the coolant heater bolt. Tighten Tighten the bolt to 2 N.m (18 lb. in). NOTE: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.
  5. Install the engine coolant heater cord to the engine coolant heater.
  6. Install the right engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
  7. Install the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  8. Lower the vehicle.
  9. Fill the engine cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .

Scheme 61

Scheme 61
Scheme 61

Important: The strap that secures the coolant heater cord to the diagonal brace is reusable. Do NOT cut this strap in order to remove it.

Scheme 62

Scheme 62: Removal Procedure
Scheme 62: Removal Procedure

Scheme 63

Scheme 63
Scheme 63
  1. Press the coolant heater strap retainer tab in order to remove coolant heater cord strap.
  2. Use wire cutters in order to remove the remaining coolant heater cord straps from the engine wiring harness.
  3. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  4. Use wire cutters in order to remove the 3 coolant heater cord lower straps (1) from the engine wiring harness.
  5. Remove the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  6. Remove the right engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
  7. Remove the engine coolant heater cord from the engine coolant heater.
  8. Remove the engine coolant heater cord.

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65: Installation Procedure
Scheme 65: Installation Procedure

Scheme 66

Scheme 66
Scheme 66
  1. Install the engine coolant heater cord to the engine coolant heater. NOTE: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.
  2. Properly route the coolant heater cord.
  3. Install new tie straps (1) in order to secure the coolant heater cord to the engine wiring harness.
  4. Install the right engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
  5. Install the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  6. Lower the vehicle.
  7. Install the reusable strap in order to secure the coolant heater cord to the diagonal brace.

Scheme 67

Scheme 67
Scheme 67

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