Engine Cooling System: Removal & Installation Pontiac Sunfire I

Surge Tank Replacement

Tools Required

J 38185 Hose Clamp Pliers

Scheme 30

Scheme 31

Scheme 32

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) . Lower the vehicle.
3. Disconnect the low coolant sensor electrical connector.
4. Remove the low coolant sensor electrical harness from the retainer.
5. Use the J 38185 in order to reposition the surge tank outlet hose clamp from the surge tank (1).
6. Remove the surge tank outlet hose from the surge tank (1).
7. Use the J 38185 in order to reposition the engine vent hose clamp from the surge tank (3).
8. Remove the engine vent hose from the surge tank (3).
9. Use the J 38185 in order to reposition the radiator vent hose clamp from the surge tank.
10. Remove the radiator vent hose from the surge tank.
11. Remove the radiator surge tank mounting bolt.
12. Remove the surge tank.

Scheme 33

Scheme 34

1. Install the surge tank. (Scheme 32)
2. Install the surge tank mounting bolt. Tighten Tighten the bolt to 10 N.m (89 lb. in).
3. Install the radiator vent hose to the surge tank.
4. Use the J 38185 in order to reposition the radiator vent hose clamp to the surge tank.
5. Install the engine vent hose to the surge tank (3).
6. Use the J 38185 in order to reposition the engine vent hose clamp to the surge tank.
7. Install the surge tank outlet hose to the surge tank (1).
8. Use the J 38185 in order to reposition the surge tank outlet hose clamp to the surge tank.
9. Install the low coolant sensor electrical connector to the retainer.
10. Connect the low coolant electrical connector.
11. Fill the cooling system at the radiator surge tank. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000).

Surge Tank Hose/Pipe Replacement

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
2. Use the J 38185 in order to reposition the surge tank pipe clamp from the surge tank outlet hose.
3. Remove the surge tank pipe from the surge tank outlet hose.
4. Use the J 38185 in order to reposition the surge tank pipe clamp from the surge tank pipe.
5. Remove the outlet hose from the surge tank pipe.

Installation Procedure

1. Install the outlet hose to the surge tank pipe.
2. Use the J 38185 in order to reposition the surge tank pipe clamp to the surge tank pipe.
3. Install the surge tank pipe to the surge tank outlet hose.
4. Use the J 38185 in order to reposition the surge tank pipe clamp.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .

Surge Tank Hose/Pipe Replacement - Outlet

Tools Required

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
2. Use the J 38185 in order to reposition the surge tank outlet hose clamp from the surge tank outlet hose.
3. Remove the surge tank outlet hose from the surge tank.
4. Use the J 38185 in order to reposition the surge tank pipe clamp from the surge tank pipe.
5. Remove the surge tank outlet hose from the surge tank pipe.

1. Install the surge tank outlet hose to the surge tank pipe.
2. Use the J 38185 in order to reposition the surge tank pipe clamp to the surge tank pipe.
3. Install the surge tank outlet hose to the surge tank.
4. Use the J 38185 in order to reposition the surge tank outlet hose clamp to the surge tank outlet hose.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000)

Radiator Hose Replacement - Inlet (2.2L - L61)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 35

Scheme 36

Scheme 37

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
2. Disconnect the electrical connector from the intake air temperature sensor.
3. Loosen the air duct clamp.
4. Remove the intake air duct resonator.
5. Use the J 38185 in order to reposition the inlet hose clamp from the water outlet (1).
6. Remove the inlet hose from the water outlet.
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Use the J 38185 in order to reposition the inlet hose clamp from the radiator.
9. Remove the inlet hose (1) from the radiator.

Scheme 38

1. Install the inlet hose (1) to the radiator. (Scheme 37)
2. Use the J 38185 in order to reposition the inlet hose clamp to the radiator.
3. Lower the vehicle.
4. Install the inlet hose to the water outlet (1).
5. Use the J 38185 in order to reposition the inlet hose clamp to the water outlet.
6. Install the intake air duct resonator.
7. Tighten the air duct clamp.
8. Connect the electrical connector to the intake air temperature sensor.
9. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000).

Radiator Hose Replacement - Outlet (2.2L - L61)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 39

Scheme 40

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
2. Use the J 38185 in order to reposition the outlet hose clamp from the cylinder head (2).
3. Remove the outlet hose from the cylinder head.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Use the J 38185 in order to reposition the outlet hose clamp from the radiator.
6. Remove the outlet hose (2) from the radiator.

Scheme 41

1. Install the outlet hose (2) to the radiator. (Scheme 40)
2. Use the J 38185 in order to reposition the outlet hose to the radiator.
3. Lower the vehicle.
4. Install the outlet hose to the cylinder head (2).
5. Use the J 38185 in order to position the outlet hose to the cylinder head.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000).

Scheme 42

Scheme 43

1. Disconnect the negative battery cable.
2. Remove the upper filler panel.
3. Remove the upper radiator mount bolts.
4. Remove the upper bolts retaining hood latch bracket to core support
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Remove the cooling fan mounting bolt.
7. Disconnect the electrical connector from the cooling fan.
8. Remove the cooling fan assembly.

Scheme 44

1. Install the cooling fan assembly.
2. Connect the electrical connector to the cooling fan. (Scheme 43)
3. Install the cooling fan mounting bolt. Tighten Tighten the cooling fan mounting bolt to 6 N.m (53 lb. in).
4. Lower the vehicle.
5. Install the upper bolts to retain hood latch bracket to core support.
6. Install the upper radiator mount bolts. Tighten Tighten bolts to 10 N.m (89 lb. in).
7. Install the upper filler panel.

Cooling Fan Relay Replacement

Tools Required

J 43244 Relay Puller Pliers

Scheme 45

1. Remove the underhood electrical center cover.
2. Using the J 43244 , remove the cooling fan relay.

Note. Installation of the proper relay is critical. If an enhanced relay - equipped with a diode - is installed into a position requiring a standard relay - equipped without a diode - excessive current will damage any components associated with the relay or its associated circuits.

1. Install the cooling fan relay.
2. Install the underhood electrical center cover.

Scheme 46

Scheme 47

Scheme 48

1. If equipped with an automatic transmission, remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REMOVAL»(ref-158669-S21827678312005033100000) .
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
3. Remove the thermostat housing to water pump feed pipe bolts.
4. Remove the thermostat housing to water pump feed pipe.
5. Remove the thermostat.

1. Install the thermostat.
2. Install the thermostat housing to water pump feed pipe. (Scheme 47)
3. Install the thermostat housing to water pump feed pipe bolt. Tighten Tighten the thermostat housing to water pump feed pipe bolt to 10 N.m (18 lb. in).
4. If equipped with an automatic transmission, install the exhaust manifold. Refer to «EXHAUST MANIFOLD INSTALLATION»(ref-158669-S37004512452005033100000).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000).

Water Pump Replacement (2.2L - L61)

Tools Required

J 43651 Water Pump Holding Tool

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. If equipped with an automatic transmission, remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REMOVAL»(ref-158669-S21827678312005033100000) .
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Remove the front fender liner. Refer to «FRONT FENDER LINER REPLACEMENT»(ref-174749-S02052349432005040800000) .
6. Remove the access plate on the water pump sprocket from the timing cover.
7. Install J 43651 to the water pump sprocket.
8. Use the access plate bolts to secure J 43651 to the engine front cover.
9. Remove the bolts that secure the sprocket to the water pump.
10. Remove the bolt (1) that secures the engine block to the water pump.
11. Remove the bolt (2) that secures the engine front cover to the water pump.
12. Remove the feed pipe that joins the thermostat housing to the water pump.
13. Remove the 2 bolts that secure the water pump to the engine block.
14. Remove the water pump.

Scheme 54

Scheme 55

Scheme 56

Scheme 57

1. Use a threaded stud in the hub to align the hub to the water pump sprocket.
2. Install the water pump.
3. Install the 2 bolts that secure the water pump to the engine block. Tighten Tighten the bolts to 20 N.m (15 lb. ft).
4. Install the feed pipe that joins the thermostat housing to the water pump. Refer to «Thermostat Replacement (2.2L - L61)»(ref-174538-S33668687992005040600000) .
5. Install the engine front cover bolt (2) and the bolt (1) that secures the engine block to the water pump. Tighten Tighten the bolts to 20 N.m (15 lb. ft).
6. Install 2 of the bolts that secure the water pump sprocket to the water pump.
7. Remove the threaded stud.
8. Install the last bolt. Tighten Tighten the bolts to 10 N.m (89 lb. in).
9. Remove J 43651.
10. Install the access plate on the water pump sprocket to the timing cover.
11. Install the bolts that secure the access plate to the timing cover. Tighten Tighten the bolts to 10 N.m (18 lb. in).
12. Install the front fender liner. Refer to «FRONT FENDER LINER REPLACEMENT»(ref-174749-S02052349432005040800000) .
13. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
14. If equipped with an automatic transmission, install the exhaust manifold. Refer to «EXHAUST MANIFOLD INSTALLATION»(ref-158669-S37004512452005033100000) .
15. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .

1. Turn the drain cock counterclockwise in order to open the drain cock.
2. Pull the stem out of the radiator body.
3. Clean or replace the seal and stem as necessary.

1. Return the stem to the radiator body.
2. Turn the drain clockwise in order to close the drain cock. (Scheme 58)

Radiator Replacement

Tools Required

J 38185 Hose Clamp Pliers

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. Disable the SIR system. Refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160361-S12052435342004021000000) .
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000) .
3. Remove the hood latch. Refer to «HOOD LATCH REPLACEMENT»(ref-174749-S03670105152005040800000) .
4. Remove the right and left headlamp assemblies. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Pontiac) in Lighting Systems.
5. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2).
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Disconnect the forward discriminating sensor harness. Refer to «ZONE 1»(ref-160361-S32163041082004021000000) .
8. Remove the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric»(ref-174538-S05466069262005040600000) .
9. Use the J 38185 in order to reposition the radiator outlet hose clamp from the radiator.
10. Remove the radiator outlet hose from the radiator.
11. Remove the lower transmission oil cooler line from the radiator.
12. Lower the vehicle.
13. Remove the hood latch support bracket and the forward discriminating sensor with the harness. Refer to «HOOD LATCH SUPPORT REPLACEMENT»(ref-174749-S31762031412005040800000) .
14. Remove the upper transmission oil cooler line from the radiator.
15. Use the J 38185 in order to reposition the radiator inlet hose from the radiator.
16. Remove the surge tank inlet hose and the clamp (1) from the radiator.
17. Remove condenser to radiator mounting bolts (2).
18. Remove the condenser from the radiator, if equipped. The radiator can be removed without discharging the A/C System.
19. Remove the radiator assembly from the vehicle.

Scheme 63

Scheme 64

Scheme 65

Scheme 66

1. Install the radiator assembly to the vehicle. (Scheme 63)
2. Install the condenser to the radiator.
3. Install condenser to radiator mounting bolts (2).
4. Use the J 38185 in order to install the surge tank hose to the radiator.
5. Route the forward discriminating sensor harness. Refer to «ZONE 1»(ref-160361-S32163041082004021000000).
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Install the lower transmission oil cooler line to the radiator. Tighten Tighten the line to 36 N.m (27 lb. ft).
8. Install the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric»(ref-174538-S05466069262005040600000).
9. Use the J 38185 in order to install the radiator outlet hose to the radiator.
10. Connect the forward discriminating sensor harness connector. Refer to «ZONE 1»(ref-160361-S32163041082004021000000).
11. Lower the vehicle.
12. Use the J 38185 in order to connect the radiator inlet hose to the radiator.
13. Install the upper transmission oil cooler line to the radiator. Tighten Tighten the upper transmission oil cooler line to 36 N.m (27 lb. ft).
14. Install the upper radiator mount bolts (1) to the upper tie bar. Tighten Tighten the bolts to 10 N.m (89 lb. in).
15. Install the hood latch support. Refer to «HOOD LATCH SUPPORT REPLACEMENT»(ref-174749-S31762031412005040800000).
16. Install the right and the left headlamp assemblies Refer to Headlamp Assembly or Headlamp Bulb Replacement (Pontiac) in Lighting Systems.
17. Install and adjust the hood latch assembly. Refer to «HOOD LATCH REPLACEMENT»(ref-174749-S03670105152005040800000).
18. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(ref-174538-S29519294792005040600000).
19. Enable the SIR system. Refer to «ZONE 1»(ref-160361-S32163041082004021000000).

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Drill out pop rivets (2) from the lower air deflector (1).
3. Remove the lower air deflector.

1. Install the lower air deflector (1) into position. (Scheme 68)
2. Install the pop rivets (2) to the lower air deflector.
3. Lower the vehicle.

Scheme 67

Scheme 68

1. Disconnect the coolant heater cord (1).
2. Remove the coolant heater bolt.
3. Remove the coolant heater.

1. Install the coolant heater. (Scheme 70)
2. Install the coolant heater bolt. Tighten Tighten the bolt to 10 N.m (89 lb. in)
3. Connect the coolant heater cord (1). (Scheme 69)

Scheme 69

Scheme 70

1. Disconnect the engine coolant heater cord (1).
2. Remove the clips from the engine mount and surge tank.

1. Install the clips from the engine mount and surge tank. see scheme 72
2. Connect the engine coolant heater cord (1). see scheme 71