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Engine Cooling System: Removal & Installation Pontiac G6 I

Cooling System (Mechanical) 6 illustrations ~5474 words

Removal Procedure

  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  3. Remove the surge tank inlet hose from the surge tank.
  4. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
  5. Disconnect the coolant level sensor wire harness connector.
  6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  7. Remove the surge tank outlet hose from the surge tank.
  8. Remove the surge tank.

Installation Procedure

  1. Install the surge tank outlet hose to the surge tank.
  2. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  3. Connect the coolant level sensor wire harness connector.
  4. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
  5. Press down on the surge tank to engage the mounting tabs.
  6. Pull upward on the surge tank to ensure that the tabs are engaged.
  7. Install the surge tank inlet hose to the surge tank.
  8. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  9. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  10. Install the surge tank cap.
CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders and the person removing the cap. Serious bodily injury may result.
  1. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  2. Remove the surge tank inlet hose from the engine.
  3. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  4. Remove the surge tank inlet hose from the surge tank.
  5. Remove the surge tank inlet hose from the vehicle.
  1. Install the surge tank inlet hose to the surge tank.
  2. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  3. Install the surge tank inlet hose to the engine.
  4. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  5. Fill the Cooling System. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders and the person removing the cap. Serious bodily injury may result.
  1. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  2. Remove the surge tank inlet hose from the engine.
  3. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  4. Remove the surge tank inlet hose from the surge tank.
  5. Remove the surge tank inlet hose clamps from the surge tank inlet hose.
  1. Install the surge tank inlet hose clamps to the surge tank inlet hose.
  2. Install the surge tank inlet hose to the surge tank.
  3. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  4. Install the surge tank inlet hose to the engine.
  5. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
CAUTIONWith a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders and the person removing the cap. Serious bodily injury may result.
  1. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  2. Remove the surge tank inlet hose from the engine.
  3. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  4. Remove the surge tank inlet hose from the surge tank.
  5. Remove the surge tank inlet hose from the vehicle.
  1. Install the surge tank inlet hose to the surge tank.
  2. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  3. Install the surge tank inlet hose to the engine.
  4. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  5. Fill the Cooling System. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the air cleaner duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L engine or «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) for the 3.9L engine.
  3. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
  4. Remove the surge tank from the surge tank bracket.
  5. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  6. Remove the surge tank outlet hose from the surge tank.
  7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  8. Remove the surge tank outlet hose from the radiator.
  9. Remove the surge tank outlet hose from the surge tank hose clip.
  10. Remove the surge tank outlet hose from the vehicle.
  1. Install the surge tank outlet hose to the surge tank hose clip.
  2. Install the surge tank outlet hose to the radiator.
  3. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  4. Install the surge tank outlet hose to the surge tank.
  5. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
  6. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
  7. Press down on the surge tank to engage the mounting tabs.
  8. Install the air cleaner duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L engine or «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) for the 3.9L engine.
  9. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  1. Partially drain the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the air cleaner outlet resonator. Refer to «AIR CLEANER OUTLET RESONATOR REPLACEMENT»(ref-243018-S31958997662006082100000) for the 2.4L engine.
  3. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
  4. Remove the surge tank from the surge tank bracket.
  5. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .
  6. Remove the surge tank outlet hose from the surge tank.
  7. Remove the surge tank outlet hose from the surge tank hose clip.
  8. Use J 38185 to reposition the surge tank outlet hose clamp at the engine and engine oil cooler.
  9. Remove the surge tank outlet hose from the engine.
  10. Remove the surge tank outlet hose from the engine oil cooler.
  11. Remove the surge tank outlet hose from the vehicle.
  1. Install the surge tank outlet hose to the surge tank hose clip.
  2. Install the surge tank outlet hose to the engine.
  3. Install the surge tank outlet hose to the engine oil cooler.
  4. Use J 38185 to reposition the surge tank outlet hose clamps at the engine and engine oil cooler.
  5. Install the surge tank outlet hose to the surge tank.
  6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .
  7. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
  8. Press down on the surge tank to engage the mounting tabs.
  9. Install the air cleaner outlet resonator. Refer to «AIR CLEANER OUTLET RESONATOR REPLACEMENT»(ref-243018-S31958997662006082100000) for the 2.4L engine.
  10. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Reposition the surge tank outlet hose clamp at engine using J 38185 .
  3. Remove the surge tank outlet hose from the engine.
  4. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
  5. Remove the surge tank from the surge tank bracket.
  6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .
  7. Remove the surge tank outlet hose from the surge tank.
  8. Remove the surge tank outlet hose clamps from the surge tank outlet hose.
  1. Install the surge tank outlet hose clamps to the surge tank outlet hose.
  2. Install the surge tank outlet hose to the surge tank.
  3. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .
  4. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
  5. Press down on the surge tank to engage the mounting tabs.
  6. Install the surge tank outlet hose to the engine.
  7. Reposition the surge outlet hose clamp at the engine using J 38185 .
  8. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .

Scheme 7

Scheme 7: Radiator Hose Replacement - Inlet (LE5)
Scheme 7: Radiator Hose Replacement - Inlet (LE5)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Drain the cooling system. Refer to Draining and Filling Cooling System .
1Hose, Radiator Inlet Tip: Using J 38185 reposition the radiator inlet hose clamps. See Special Tools .

Radiator Hose Replacement - Inlet (LE5)

Scheme 8

Scheme 8: Radiator Hose Replacement - Inlet (LX9)
Scheme 8: Radiator Hose Replacement - Inlet (LX9)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Drain the cooling system. Refer to Draining and Filling Cooling System .
1Hose, Radiator Inlet Tip: Using J 38185 reposition the radiator inlet hose clamps. See Special Tools .

Radiator Hose Replacement - Inlet (LX9)

Scheme 9

Scheme 9: Radiator Hose Replacement - Inlet (LZ9)
Scheme 9: Radiator Hose Replacement - Inlet (LZ9)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Drain the cooling system. Refer to Draining and Filling Cooling System .
1Hose, Radiator Inlet Tip: Using J 38185 reposition the radiator inlet hose clamps. See Special Tools .

Radiator Hose Replacement - Inlet (LZ9)

Scheme 10

Scheme 10: Radiator Hose Replacement - Outlet (LE5)
Scheme 10: Radiator Hose Replacement - Outlet (LE5)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Drain the cooling system. Refer to Draining and Filling Cooling System .
1Hose, Radiator Outlet Tip: Using J 38185 reposition the radiator outlet hose clamps. See Special Tools .

Radiator Hose Replacement - Outlet (LE5)

Scheme 11

Scheme 11: Radiator Hose Replacement - Outlet (LX9)
Scheme 11: Radiator Hose Replacement - Outlet (LX9)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Drain the cooling system. Refer to Draining and Filling Cooling System .
1Hose, Radiator Outlet Tip: Using J 38185 reposition the radiator outlet hose clamps. See Special Tools .

Radiator Hose Replacement - Outlet (LX9)

Scheme 12

Scheme 12: Radiator Hose Replacement - Outlet (LZ9)
Scheme 12: Radiator Hose Replacement - Outlet (LZ9)
CalloutComponent Name
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Drain the cooling system. Refer to Draining and Filling Cooling System .
1Hose, Radiator Outlet Tip: Using J 38185 reposition the radiator outlet hose clamps. See Special Tools .

Radiator Hose Replacement - Outlet (LZ9)

  1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the air cleaner air duct. Refer to the following: «AIR CLEANER OUTLET RESONATOR REPLACEMENT»(ref-243018-S31958997662006082100000) for the 2.4L engine. «AIR CLEANER INTAKE DUCT REPLACEMENT»(ref-242989-S27993374472006082100000) for the 3.5L engine, «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-242992-S17333111132006082100000) for the 3.9L engine
  3. Remove the upper radiator air deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-243023-S38340268302006082100000) .
  4. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-243013-S16834146642006082100000) .
  5. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
  6. Remove the upper radiator support bracket bolts.
  7. Remove the upper radiator support brackets.
  8. Pry upward on the fan shroud tabs at the radiator clips to release the fan shroud from the radiator.
  9. Remove the lower radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-243023-S35124382672006082100000) .
  10. Lower the vehicle.
  11. Remove the radiator inlet hose from the radiator. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000) .
  12. Remove the radiator outlet hose from the radiator. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000) .
  13. Disconnect the cooling fan wire harness connectors.
  14. Remove the A/C compressor hose assembly. Refer to «COMPRESSOR HOSE ASSEMBLY REPLACEMENT (LE5)»(ref-243028-S36008869252006082100000) .
  15. Raise the vehicle.
  16. Remove the lower radiator support bracket bolts.
  17. Remove the lower radiator support brackets.
  18. Remove the transmission oil cooler pipe clip from the fan shroud.
  19. Remove the fan shroud assembly.
  1. Install the fan shroud assembly.
  2. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-243013-S16834146642006082100000) .
  3. Install the transmission oil cooler pipe clip to the fan shroud.
  4. Install the lower radiator support brackets.
  5. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  6. Install the cooling fan wire harness connectors.
  7. Install the radiator outlet hose to the radiator. Refer to «Radiator Hose Replacement - Outlet (LE5)»(ref-243023-S37048063472006082100000) .
  8. Install the lower radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-243023-S35124382672006082100000) .
  9. Lower the vehicle.
  10. Snap fan shroud tabs into the radiator clips.
  11. Remove the rope attached to the condenser and upper tie bar.
  12. Install the upper radiator support brackets.
  13. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  14. Install the radiator inlet hose to the radiator. Refer to «Radiator Hose Replacement - Inlet (LE5)»(ref-243023-S04811635882006082100000) .
  15. Install the A/C compressor hose assembly. Refer to «COMPRESSOR HOSE ASSEMBLY REPLACEMENT (LE5)»(ref-243028-S36008869252006082100000) .
  16. Install the upper radiator air deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-243023-S38340268302006082100000) .
  17. Install the air cleaner air duct. Refer to the following: «AIR CLEANER OUTLET RESONATOR REPLACEMENT»(ref-243018-S31958997662006082100000) for the 2.4L engine. «AIR CLEANER INTAKE DUCT REPLACEMENT»(ref-242989-S27993374472006082100000) for the 3.5L engine. «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-242992-S17333111132006082100000) for the 3.9L engine.
  18. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  19. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(ref-243020-S36429249652006082100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the water pump drain plug and drain the coolant from the engine block at the water pump drain.
  3. Lower the vehicle.
  4. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  5. Disconnect the heated oxygen sensor (HO2S) electrical connector clip from the bracket.
  6. Remove the ECT sensor.
  7. If the vehicle is not equipped an engine oil cooler proceed with the following steps, otherwise proceed to step 12.
  8. Reposition the radiator outlet hose clamp at the surge tank.
  9. Remove the radiator outlet hose from the surge tank.
  10. Reposition the radiator outlet hose clamp at the thermostat housing.
  11. Remove the radiator outlet hose from the thermostat housing. Proceed to step 16.
  12. If the vehicle is equipped with an engine oil cooler, reposition the surge tank outlet hose clamp at the thermostat housing.
  13. Remove the surge tank outlet hose from the thermostat housing.
  14. Reposition the radiator outlet hose clamp at the thermostat housing.
  15. Remove the radiator outlet hose from the thermostat housing.
  16. Remove the exhaust heat shield bolts.
  17. Remove the exhaust heat shield.
  18. Remove the exhaust heat shield.
  19. Disconnect the heater inlet (1) and outlet (2) hoses from the thermostat housing pipes.
  20. Remove the thermostat housing bolts.
  21. Remove the thermostat housing from the vehicle.
  22. Remove the water transfer pipe from the thermostat housing, if necessary.
  23. Remove and discard the water transfer pipe O-ring seals, if necessary.
  24. Remove the thermostat housing cover bolts and cover, if necessary.
  25. Remove the thermostat, if necessary.
  26. Remove and discard the thermostat housing O-ring seal, if necessary.
  27. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being reused.
  1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
  2. Install the thermostat, if necessary.
  3. Install the thermostat housing cover bolts, if necessary. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install a NEW thermostat housing to engine O-ring seal onto the thermostat housing.
  5. Load the thermostat housing assembly into position while the vehicle is lowered.
  6. Install NEW O-ring seals onto the water feed pipe.
  7. Install the water feed pipe into the thermostat housing aligning locator tab.
  8. Align the water pipe to water pump.
  9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  10. Position the thermostat housing against the engine.
  11. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  12. Connect the heater inlet (1) and outlet (2) hoses to the thermostat housing pipes.
  13. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
  14. Install the exhaust heat shield.
  15. Install the exhaust heat shield bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
  16. If the vehicle is equipped with an engine oil cooler proceed with the following steps, otherwise proceed to step 21.
  17. Install the radiator outlet hose to the thermostat housing.
  18. Position the radiator outlet hose clamp at the thermostat housing.
  19. Install the surge tank outlet hose to the thermostat housing.
  20. Position the surge tank outlet hose clamp at the thermostat housing. Proceed to step 25.
  21. If the vehicle is not equipped an engine oil cooler, install the radiator outlet hose to the thermostat housing.
  22. Position the radiator outlet hose clamp at the thermostat housing.
  23. Install the radiator outlet hose to the surge tank.
  24. Position the radiator outlet hose clamp at the surge tank.
  25. Apply sealant to the threads of the ECT sensor. Refer to «SEALERS, ADHESIVES AND LUBRICANTS»(ref-243010-S16900210712006082100000) .
  26. Install the ECT sensor. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  27. Connect the ECT sensor electrical connector (1).
  28. Connect the HO2S electrical connector clip to the bracket.
  29. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.
  30. Install the water pump drain plug. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  31. Verify the drain valves at the radiator and water pump are closed.
  32. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  33. Verify the repair and inspect for any leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L engine.
  3. Disconnect the surge tank hose from the coolant outlet.
  4. Remove the thermostat housing to intake manifold bolts.
  5. Remove the thermostat housing outlet and thermostat.
  1. Install the thermostat and housing outlet.
  2. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 25 N.m (18 lb ft).
  3. Install the air cleaner outlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L engine.
  4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  5. Inspect the system for leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
  3. Reposition the radiator outlet hose clamp at the thermostat housing.
  4. Remove the radiator outlet hose from the thermostat housing.
  5. Remove the thermostat housing bolt/stud.
  6. Remove the thermostat housing and gasket.
  7. Clean the gasket surfaces.
  1. Position a NEW gasket and the thermostat housing to the engine block.
  2. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
  3. Install the radiator outlet hose to the thermostat housing.
  4. Position the radiator outlet hose clamp at the thermostat housing.
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  7. Inspect the system for leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. If the vehicle is not equipped an engine oil cooler proceed with the following steps, otherwise proceed to step 7.
  3. Reposition the radiator outlet hose clamp at the surge tank.
  4. Remove the radiator outlet hose from the surge tank.
  5. Reposition the radiator outlet hose clamp at the thermostat housing.
  6. Remove the radiator outlet hose from the thermostat housing. Proceed to step 11.
  7. If the vehicle is equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the thermostat housing.
  8. Remove the radiator outlet hose from the thermostat housing.
  9. Reposition the surge tank outlet hose clamp at the thermostat housing.
  10. Remove the surge tank outlet hose from the thermostat housing.
  11. Remove the thermostat housing cover bolts and cover.
  12. Remove the thermostat.
  13. Remove and discard the thermostat housing O-ring seal.
  1. Install a NEW thermostat housing cover O-ring seal.
  2. Install the thermostat.
  3. Install the thermostat housing cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. If the vehicle is equipped with an engine oil cooler proceed with the following steps, otherwise proceed to step 9.
  5. Install the radiator outlet hose to the thermostat housing.
  6. Position the radiator outlet hose clamp at the thermostat housing.
  7. Install the surge tank outlet hose to the thermostat housing.
  8. Position the surge tank outlet hose clamp at the thermostat housing. Proceed to step 13.
  9. If the vehicle is not equipped an engine oil cooler, install the radiator outlet hose to the thermostat housing.
  10. Position the radiator outlet hose clamp at the thermostat housing.
  11. Install the radiator outlet hose to the surge tank.
  12. Position the radiator outlet hose clamp at the surge tank.
  13. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  1. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L (LX9) engine.
  2. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  3. Use the J 38185 in order to reposition the hose clamp from the thermostat housing. See «Special Tools»(ref-243023-S04058732852006082100000) .
  4. Remove the radiator inlet hose from the thermostat housing.
  5. Remove the thermostat housing bolts.
  6. Remove the thermostat housing.
  7. Remove the thermostat.
  8. Clean and inspect the thermostat housing gasket mating surfaces.
  1. Install the thermostat.
  2. Install the thermostat housing.
  3. Install the thermostat housing bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  4. Install the radiator inlet hose to the thermostat housing.
  5. Use the J 38185 in order to reposition and install the hose clamp to the thermostat housing. See «Special Tools»(ref-243023-S04058732852006082100000) .
  6. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L (LX9) engine.
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
  3. Reposition the radiator outlet hose clamp at the thermostat housing.
  4. Remove the radiator outlet hose from the thermostat housing.
  5. Remove the thermostat housing bolt/stud.
  6. Remove the thermostat housing and gasket.
  7. Remove the thermostat.
  8. Clean the gasket surfaces.
  1. Install a NEW thermostat.
  2. Position a NEW gasket and the thermostat housing to the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-242977-S25864542072006082100000) .
  3. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
  4. Install the radiator outlet hose to the thermostat housing.
  5. Position the radiator outlet hose clamp at the thermostat housing.
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-242992-S17333111132006082100000) .
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  8. Inspect the system for leaks.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
  2. Remove the generator. Refer to «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) .
  3. Remove the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(ref-243015-S13699848292006082100000) .
  4. Remove the power steering pump. Refer to «Power Steering Pump Replacement»(ref-243012-S25166776782006082100000) .
  5. Reposition the radiator surge tank inlet hose clamp at the surge tank inlet pipe.
  6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way.
  7. Remove the radiator surge tank pipe bolts.
  8. Remove the radiator surge tank pipe from the crossover pipe.
  9. Reposition the radiator inlet hose clamp at the crossover pipe.
  10. Remove the radiator inlet hose from the crossover pipe.
  11. Reposition the thermal bypass hose clamp at the crossover pipe.
  12. Remove the thermal bypass hose from the crossover pipe.
  13. Remove the coolant crossover pipe bolts.
  14. Remove the coolant crossover pipe.
  1. Position the coolant crossover pipe to the cylinder heads.
  2. Install the coolant crossover pipe bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  3. Install the thermal bypass hose to the crossover pipe.
  4. Position the thermal bypass hose clamp at the crossover pipe.
  5. Install the radiator inlet hose to the crossover pipe.
  6. Position the radiator inlet hose clamp at the crossover pipe.
  7. Install the radiator surge tank pipe to the crossover pipe.
  8. Install the radiator surge tank pipe bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  9. Install the radiator surge tank inlet hose to the inlet pipe.
  10. Position the radiator surge tank inlet hose clamp at the surge tank inlet pipe.
  11. Install the power steering pump. Refer to «Power Steering Pump Replacement»(ref-243012-S25166776782006082100000) .
  12. Install the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(ref-243015-S13699848292006082100000) .
  13. Install the generator. Refer to «Generator Replacement (3.9L)»(ref-242993-S25530803482006082100000) .
  14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243015-S06972132842006082100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
  3. Carefully remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L engine.
  4. Remove the spark plug wires at the left bank.
  5. Using the J 38185 , reposition the hose clamp at the thermostat housing. See «Special Tools»(ref-243023-S04058732852006082100000) .
  6. Remove the upper radiator hose from the housing.
  7. Disconnect the heater outlet hose from the thermostat bypass pipe.
  8. Remove the thermostat bypass pipe-to-throttle body nut.
  9. Using the J 38185 , reposition the hose clamp at the thermostat bypass pipe. See «Special Tools»(ref-243023-S04058732852006082100000) .
  10. Disconnect the thermostat bypass pipe hose.
  11. Remove the thermostat bypass pipe-to-engine front cover bolt.
  12. Remove the thermostat bypass pipe.
  1. Install the thermostat bypass pipe.
  2. Install the thermostat bypass pipe-to-engine front cover bolt. Tighten: Tighten the bolt to 11 N.m (98 lb in).
  3. Connect the thermostat bypass pipe hose.
  4. Using the J 38185 , reposition and secure the hose clamp at the thermostat bypass pipe. See «Special Tools»(ref-243023-S04058732852006082100000) .
  5. Install the thermostat bypass pipe to the throttle body stud.
  6. Install the thermostat bypass pipe-to-throttle body nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
  7. Connect the heater outlet hose to the thermostat bypass pipe.
  8. Connect the inlet hose at the thermostat housing.
  9. Using the J 38185 , reposition and install the inlet hose clamp at the thermostat housing. See «Special Tools»(ref-243023-S04058732852006082100000) .
  10. Install the spark plug wires at the left bank.
  11. Install the air cleaner assembly. Refer to «Air Cleaner Intake Duct Replacement»(ref-242989-S27993374472006082100000) for the 3.5L engine.
  12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  13. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-243014-S31465927582006082100000) .
  14. Inspect for leaks.
  1. Remove the thermostat housing. Refer to «Thermostat Housing Replacement (2.4L)»(ref-243023-S15775634622006082100000) .
  2. Remove the coolant heater. Refer to «Coolant Heater Replacement (2.4L)»(ref-243023-S09707627772006082100000) .
  3. Remove the water pump access plate from the front cover.
  4. Install the J 43651 into position.
  5. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  6. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  7. Remove the 3 inner water pump sprocket to water pump bolts through the holes in the water pump holding tool.
  8. Remove the 2 water pump bolts.
  9. Remove the rear 2 water pump bolts.
  10. Remove the engine wiring harness clip nut from the water pump stud.
  11. Remove the engine wiring harness clip from the stud.
  12. Remove the water pump.
  1. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.
  2. Install the water pump drain Plug. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  3. Using the J 25025-5 or a guide pin align the pin with the water pump holding tool.
  4. Position the water pump against the engine block and hand tighten the water pump bolts.
  5. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  6. Tighten the water pump sprocket bolts last. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  7. Remove the J 43651 .
  8. Install the coolant heater. Refer to «Coolant Heater Replacement (2.4L)»(ref-243023-S09707627772006082100000) .
  9. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  10. Install the thermostat housing. Remove the thermostat housing. Refer to «Thermostat Housing Replacement (2.4L)»(ref-243023-S15775634622006082100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Loosen the water pump pulley bolts.
  3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) for the 3.5L engine.
  4. Remove the water pump pulley bolts and pulley.
  5. Remove the water pump bolts, pump and gasket.
  6. Clean the water pump mating surfaces.
  1. Install the water pump gasket and pump (1).
  2. Install the water pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. Install the water pump pulley and bolt until snug.
  4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243014-S07327488402006082100000) for the 3.5L engine.
  5. Install the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  7. Inspect for leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Loosen the water pump pulley bolts.
  3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
  4. Remove the water pump pulley bolts and pulley.
  5. Remove the water pump bolts.
  6. Remove the water pump and gasket.
  7. Clean the water pump mating surfaces.
  1. Position a NEW water pump gasket and the water pump to the engine front cover.
  2. Install the water pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. Install the water pump pulley and bolts.
  4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-243015-S14538549132006082100000) .
  5. Tighten the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  7. Inspect for leaks.
  1. Remove the cooling fan and shroud assembly. Refer to «Cooling Fan and Shroud Replacement»(ref-243023-S29282108962006082100000) .
  2. Remove and discard the condenser mounting bolts.
  3. Push upward on the condenser and downward on the radiator to unsnap the condenser mounting tabs from the radiator clips.
  4. Remove and discard the condenser mounting nuts from the radiator.
  5. Remove the radiator from the vehicle.
  1. Install the radiator to the vehicle.
  2. Push upward on the radiator and downward on the condenser to snap the condenser mounting tabs into the radiator clips.
  3. Install new condenser mounting nut to the radiator. Tighten: Tighten the bolts to 6 N.m (53 lb in).
  4. Install new condenser mounting bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
  5. Install the cooling fan and shroud assembly. Refer to «Cooling Fan and Shroud Replacement»(ref-243023-S29282108962006082100000) .
  1. Remove the upper front bumper support. Refer to «FASCIA SUPPORT REPLACEMENT - FRONT BUMPER UPPER»(ref-243006-S01195712592006082100000) .
  2. Remove the upper radiator support bracket retaining bolt.
  3. Remove the upper radiator support bracket.
  1. Install the upper radiator support bracket.
  2. Install the upper radiator support bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Install the upper front bumper support. Refer to «FASCIA SUPPORT REPLACEMENT - FRONT BUMPER UPPER»(ref-243006-S01195712592006082100000) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
  2. Remove the lower radiator air deflector retainers.
  3. Remove the lower radiator air deflector.
  1. Install the lower radiator air deflector.
  2. Install the lower radiator air deflector retainers.
  3. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
  2. Remove the lower radiator air baffle. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-243023-S35124382672006082100000) .
  3. Remove the side radiator air deflector retainers.
  4. Remove the side radiator air deflector.
  1. Install the side radiator air deflector.
  2. Install the side radiator air deflector retainer.
  3. Install lower radiator air baffle. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-243023-S35124382672006082100000) .
  4. Install the upper front fascia support. Refer to «FASCIA SUPPORT REPLACEMENT - FRONT BUMPER UPPER»(ref-243006-S01195712592006082100000) .
  1. Remove the front bumper upper fascia support. Refer to «Fascia Support Replacement - Front Bumper Upper»(ref-243006-S01195712592006082100000) in Bumpers.
  2. Remove the upper radiator air deflector.
  1. Install the upper radiator air deflector.
  2. Install the front bumper upper fascia support. Refer to «Fascia Support Replacement - Front Bumper Upper»(ref-243006-S01195712592006082100000) in Bumpers.
  1. Disconnect the coolant heater cord.
  2. Remove the coolant heater bolt.
  3. Remove the coolant heater.
  1. Install the coolant heater.
  2. Install the coolant heater bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Connect the coolant heater cord.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  2. Disconnect the engine coolant heater cord from the engine coolant heater.
  3. Remove the engine coolant heater.
  4. Clean the engine coolant heater opening.
  1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant heater, if necessary.
  2. Install the engine coolant heater. Tighten: Tighten the coolant heater to 60 N.m (44 lb ft).
  3. Connect the engine coolant heater cord to the engine coolant heater.
  4. Lower the vehicle.
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
  6. Inspect for leaks.
  1. Disconnect the engine coolant heater cord.
  2. Disconnect the clip from the air conditioning (A/C) line.
  3. Disconnect the clip from the front compartment inner side upper rail.
  4. Remove the heater cord.
  1. Install the coolant heater.
  2. Connect the clip to the front compartment inner side upper rail.
  3. Connect the clip to the A/C line.
  4. Connect the engine coolant heater cord.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
  2. Disconnect the engine coolant heater cord from the engine coolant heater.
  3. Remove the coolant heater cord clip from the automatic transmission range selector lever cable bracket.
  4. Lower the vehicle.
  5. Remove the coolant heater cord from between the shock tower and side rail.
  1. Install the coolant heater cord between the shock tower and side rail.
  2. Raise and support the vehicle.
  3. Install the coolant heater cord clip to the automatic transmission range selector lever cable bracket.
  4. Connect the engine coolant heater cord to the engine coolant heater.
  5. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) in General Information.
  2. Disconnect the engine coolant heater cord from the engine coolant heater.
  3. If equipped with the manual transmission, remove the coolant heater cord clips from the transmission range selector lever cable bracket.
  4. If equipped with the automatic transmission, remove the coolant heater cord clips from the transmission range selector lever cable bracket.
  5. Lower the vehicle.
  6. Remove the coolant heater cord from between the shock tower and side rail.
  1. Install the coolant heater cord between the shock tower and side rail.
  2. Raise and support the vehicle.
  3. If equipped with the automatic transmission, install the coolant heater cord clips to the transmission range selector lever cable bracket.
  4. If equipped with the manual transmission, Install the coolant heater cord clips to the transmission range selector lever cable bracket.
  5. Connect the engine coolant heater cord to the engine coolant heater.
  6. Lower the vehicle.

More articles — Engine Cooling System