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Engine Cooling System: Removal & Installation Pontiac Solstice I

Cooling System (Mechanical) 5 illustrations ~2639 words

Removal Procedure

  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-267961-S05170217922007101700000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  3. Reposition the radiator surge tank hose clamp (1) at the turbocharger coolant feed pipe fitting.
  4. Remove the radiator surge tank hose from the turbocharger coolant feed pipe fitting and reposition out of the way.
  5. Remove the charge air bypass valve solenoid tube from the turbocharger coolant feed pipe clips (4).
  6. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
  7. Remove the turbocharger coolant feed pipe fitting (2) from the cylinder head.
  8. Remove the turbocharger coolant feed pipe bracket bolt (3) from the cylinder head.
  9. Remove the turbocharger coolant feed pipe clips from the camshaft cover and remove the turbocharger coolant feed pipe from the vehicle.
  10. Remove the gaskets from both banjo fittings on the turbocharger coolant feed pipe.

Installation Procedure

  1. Install NEW gaskets to both banjo fittings on the turbocharger coolant feed pipe.
  2. Position the turbocharger coolant feed pipe to the engine and install the clips to the camshaft cover.
  3. Install the turbocharger coolant feed pipe fitting (2) to the cylinder head. Tighten: Tighten the fitting to 35 N.m (26 lb ft).
  4. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
  5. Install the coolant feed pipe bracket bolt (3) to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  6. Install the charge air bypass valve solenoid tube to the turbocharger coolant feed pipe clips (4).
  7. Position and install the radiator surge tank hose to the turbocharger coolant feed pipe fitting.
  8. Position the radiator surge tank hose clamp (1) at the turbocharger coolant feed pipe fitting.
  9. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-267961-S05170217922007101700000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LNF)»(ref-267921-S05319258572007101700000) or «Catalytic Converter Replacement (LE5)»(ref-267921-S16506809992007101700000) .
  3. Remove the turbocharger coolant return pipe bolt at the turbocharger.
  4. Remove the turbocharger coolant return pipe bolt at the thermostat housing.
  5. Remove the gaskets from both banjo fittings on the turbocharger coolant return pipe.
  1. Install NEW gaskets to both banjo fittings on the turbocharger coolant return pipe.
  2. Install the turbocharger coolant return pipe bolt at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
  3. Install the turbocharger coolant return pipe bolt at the thermostat housing. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
  4. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LNF)»(ref-267921-S05319258572007101700000) or «Catalytic Converter Replacement (LE5)»(ref-267921-S16506809992007101700000) .
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
IMPORTANTA drain has been provided at the bottom of the water pump for engine block coolant drainage.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt. Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
  3. Lower the vehicle.
  4. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  5. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
  6. Remove the ECT sensor, if necessary.
  7. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
  8. Remove the radiator outlet hose from the thermostat housing and reposition out of the way.
  9. Remove the exhaust manifold. Refer to «Muffler Replacement (LNF)»(ref-267921-S05154646172007101700000) or «Muffler Replacement (LE5)»(ref-267921-S04534106972007101700000) .
  10. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  11. Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
  12. Remove the thermostat housing bolts.
  13. Remove the thermostat housing from the vehicle.
  14. Remove the water transfer pipe from the thermostat housing, if necessary.
  15. Remove and discard the water transfer pipe o-ring seals, if necessary.
  16. Remove the thermostat housing cover bolts and cover, if necessary.
  17. Remove the thermostat, if necessary.
  18. Remove and discard the thermostat housing O-ring seal, if necessary.
  19. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.
  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 gasket onto the thermostat housing.
  5. Load the thermostat housing assembly into position while the vehicle is lowered.
  6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-267916-S02548706122007101700000) .
  7. Install NEW O-ring seals onto the water feed pipe.
  8. Install the water feed pipe into the thermostat housing aligning locator tab.
  9. Align the water pipe to water pump.
  10. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  11. Lower the vehicle.
  12. Position the thermostat housing against the engine.
  13. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  14. Connect the heater inlet (2) and outlet (1) hoses to the thermostat housing pipes.
  15. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
  16. Install the exhaust manifold. Refer to «Muffler Replacement (LNF)»(ref-267921-S05154646172007101700000) or «Muffler Replacement (LE5)»(ref-267921-S04534106972007101700000) .
  17. Install the radiator outlet hose to the thermostat housing.
  18. Position the radiator outlet hose clamp (2) at the thermostat housing.
  19. If reinstalling the old sensor, coat the threads with sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-267961-S25738625502007101700000) .
  20. Install the ECT sensor, if necessary. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  21. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
  22. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  23. Verify the drain plugs at the radiator and water pump are tightened.
  24. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  25. Lower the vehicle.
  26. Inspect for any leaks.
IMPORTANTA drain has been provided at the bottom of the water pump for engine block coolant drainage.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt. Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
  3. Lower the vehicle.
  4. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  5. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
  6. Remove the ECT sensor, if necessary.
  7. Reposition the radiator outlet hose clamp at the thermostat housing.
  8. Remove the radiator outlet hose from the thermostat housing.
  9. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
  10. Remove the exhaust heat shield bolts.
  11. Remove the exhaust heat shield.
  12. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  13. Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
  14. Remove the thermostat housing bolts.
  15. Remove the thermostat housing from the vehicle.
  16. Remove the water transfer pipe from the thermostat housing, if necessary.
  17. Remove and discard the water transfer pipe O-ring seals, if necessary.
  18. Remove the thermostat housing cover bolts and cover, if necessary.
  19. Remove the thermostat, if necessary.
  20. Remove and discard the thermostat housing O-ring seal, if necessary.
  21. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.
  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 gasket onto the thermostat housing.
  5. Load the thermostat housing assembly into position while the vehicle is lowered.
  6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-267916-S02548706122007101700000) .
  7. Install NEW O-ring seals onto the water feed pipe.
  8. Install the water feed pipe into the thermostat housing aligning locator tab.
  9. Align the water pipe to water pump.
  10. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  11. Lower the vehicle.
  12. Position the thermostat housing against the engine.
  13. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  14. Connect the heater inlet (2) and outlet (1) hoses to the thermostat housing pipes.
  15. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
  16. Install the exhaust heat shield.
  17. Install the exhaust heat shield bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
  18. Install the radiator outlet hose to the thermostat housing.
  19. Reposition the radiator outlet hose clamp at the thermostat housing.
  20. Install the radiator outlet hose clip (1) to the outlet hose bracket.
  21. If reinstalling the old sensor, coat the threads with sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-267961-S25738625502007101700000) .
  22. Install the ECT sensor, if necessary. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  23. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
  24. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  25. Verify the drain plugs at the radiator and water pump are tightened.
  26. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  27. Lower the vehicle.
  28. Inspect for any leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  2. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  3. Reposition the radiator outlet hose clamp (1) at the thermostat housing.
  4. Remove the radiator outlet hose from the thermostat housing.
  5. Remove the thermostat housing cover bolts and cover.
  6. Remove the thermostat.
  7. Remove and discard the thermostat housing O-ring seal.
  1. Install a NEW thermostat housing cover O-ring seal onto the housing.
  2. Install the thermostat.
  3. Install the thermostat housing cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install the radiator outlet hose to the thermostat housing.
  5. Reposition the radiator outlet hose clamp (1) at the thermostat housing.
  6. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  2. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  3. Reposition the radiator outlet hose clamp at the thermostat housing.
  4. Remove the radiator outlet hose from the thermostat housing.
  5. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
  6. Remove the thermostat housing cover bolts and cover.
  7. Remove the thermostat.
  8. Remove and discard the thermostat housing O-ring seal.
  1. Install a NEW thermostat housing cover O-ring seal onto the housing.
  2. Install the thermostat.
  3. Install the thermostat housing cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install the radiator outlet hose to the thermostat housing.
  5. Reposition the radiator outlet hose clamp at the thermostat housing.
  6. Install the radiator outlet hose clip (1) to the outlet hose bracket.
  7. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement»(ref-267926-S17961782502007101700000) .
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-267943-S25939776342007101700000) .
  2. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-267956-S27394310662007101700000) or «Engine Coolant Thermostat Housing Replacement (LE5)»(ref-267956-S36346207942007101700000) .
  3. Remove the water pump access plate from the front cover.
  4. Drain the coolant from the water pump using the plug at the bottom of the pump.
  5. Install the J 43651 (1) into position. See «Special Tools»(ref-267956-S32146669372007101700000) .
  6. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  7. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  8. Remove the 3 inner water pump sprocket to water pump blots.
  9. Remove the 2 water pump bolts.
  10. Remove the rear 2 water pump bolts.
  11. Remove the water pump.
  12. Remove and discard the water pump O-ring seal.
  1. Install a NEW water pump O-ring seal.
  2. Using the guide pin, align the pin with the water pump holding tool.
  3. Position the water pump against the engine block and hand tighten the water pump bolts.
  4. 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).
  5. Tighten the water pump sprocket bolts last. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  6. Remove the J 43651 (1). See «Special Tools»(ref-267956-S32146669372007101700000) .
  7. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-267956-S27394310662007101700000) or «Engine Coolant Thermostat Housing Replacement (LE5)»(ref-267956-S36346207942007101700000) .
  9. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-267943-S25939776342007101700000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-267943-S25939776342007101700000) .
  2. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-267956-S27394310662007101700000) or «Engine Coolant Thermostat Housing Replacement (LE5)»(ref-267956-S36346207942007101700000) .
  3. Remove the water pump access plate from the front cover.
  4. Drain the coolant from the water pump using the plug at the bottom of the pump.
  5. Install the J 43651 into position. See «Special Tools»(ref-267956-S32146669372007101700000) .
  6. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  7. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  8. Remove the 3 inner water pump sprocket to water pump blots.
  9. Remove the 2 water pump bolts.
  10. Remove the rear 2 water pump bolts.
  11. Remove the water pump.
  12. Remove and discard the water pump O-ring seal.
  1. Install a NEW water pump O-ring seal.
  2. Using the guide pin, align the pin with the water pump holding tool.
  3. Position the water pump against the engine block and hand tighten the water pump bolts.
  4. 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).
  5. Tighten the water pump sprocket bolts last. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  6. Remove the J 43651 . See «Special Tools»(ref-267956-S32146669372007101700000) .
  7. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(ref-267956-S27394310662007101700000) or «Engine Coolant Thermostat Housing Replacement (LE5)»(ref-267956-S36346207942007101700000) .
  9. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-267943-S25939776342007101700000) .

Radiator Drain Cock Replacement

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. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-267916-S02548706122007101700000) .
  2. Place a drain pan under the right side lower radiator mount.
  3. Loosen the radiator drain cock.
  1. Tighten the radiator drain cock. Tighten the radiator drain cock by hand only.
  2. Lower the vehicle.
  3. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE-47716)»(ref-267956-S11120049512007101700000) or «Draining and Filling Cooling System (2.4L LE5 Only)»(ref-267956-S38377302862007101700000) .

Scheme 8

Scheme 8: Radiator Replacement
Scheme 8: Radiator Replacement
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Draining and Filling Cooling System (GE-47716) or Draining and Filling Cooling System (2.4L LE5 Only) . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement . Remove the fan shroud assembly. Refer to Cooling Fan and Shroud Replacement . Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement . Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement . Remove the surge tank inlet hose from radiator. Refer to Surge Tank Hose/Pipe Replacement - Inlet . Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement .
1A/C Condenser Bolt NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2A/C Condenser Bracket
3Radiator Assembly
NOTE
Refer to Fastener Notice .

Radiator Replacement

Scheme 9

Scheme 9: Radiator Support Bracket Replacement
Scheme 9: Radiator Support Bracket Replacement
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Stud, Air Cleaner Tighten: 10 N.m (89 lb in)
2Nut, Radiator Upper Bracket Tighten: 9 N.m (80 lb in)
3Bracket Assembly, Radiator Upper
NOTE
Refer to Fastener Notice .

Radiator Support Bracket Replacement

Scheme 10

Scheme 10: Radiator Air Lower Baffle and Deflector Replacement
Scheme 10: Radiator Air Lower Baffle and Deflector Replacement
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the radiator side air deflectors. Refer to Radiator Air Baffle and Deflector Replacement - Side .
1Push Pin, Radiator Air Deflector - Front (Qty: 4)
2Bolt, Radiator Air Deflector - Front (Qty: 2) Tighten: 9 N.m (80 lb in)
3Deflector Assembly, Radiator Air - Front

Radiator Air Lower Baffle and Deflector Replacement

Scheme 11

Scheme 11: Radiator Air Baffle and Deflector Replacement - Side
Scheme 11: Radiator Air Baffle and Deflector Replacement - Side
CalloutComponent Name
NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Pin, Push
2Seal Assembly, Radiator Air Lower Side
NOTE
Refer to Fastener Notice .

Radiator Air Baffle and Deflector Replacement - Side

Scheme 12

Scheme 12: Radiator Air Upper Baffle and Deflector Replacement
Scheme 12: Radiator Air Upper Baffle and Deflector Replacement
CalloutComponent Name
Preliminary Procedure: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Radiator Front Air Deflector Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 9 N.m (80 lb in)
2Radiator Front Air Deflector Assembly
3Shroud Air inlet Retainer
4Air Inlet Shroud
NOTE
Refer to Fastener Notice .

Radiator Air Upper Baffle and Deflector Replacement

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