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Engine Cooling System: Removal & Installation Pontiac Vibe II

Cooling System (Mechanical) 2 illustrations ~2682 words

Removal Procedure

  1. Disconnect cable from negative battery terminal.
  2. Remove the left engine under cover.
  3. Remove the right engine under cover.
  4. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  5. Separate the radiator reserve tank assembly. Refer to «Radiator Surge Tank Replacement»(ref-341924-S25613335242009091700000) .
  6. Remove the v-ribbed belt. Refer to «Drive Belt Replacement»(ref-341922-S02680809022009091700000) .
  7. Remove the generator assembly. Refer to «Generator Replacement (2.4L)»(ref-341923-S15541119442009091700000) .
  8. Remove the right engine mounting insulator subassembly. Refer to «Engine Mount Replacement»(ref-341922-S22573497302009102800000) .
  9. Using EN 46104 , remove the 4 bolts and water pump pulley.
  10. Remove the clamp of the crankshaft position sensor from the water pump.
  11. Disconnect the wire of the crankshaft position sensor from the clamp bracket.
  12. Remove the 4 bolts, 2 nuts and clamp bracket.
  13. Using a screwdriver, pry between the water pump and cylinder block, and then remove the water pump.

Installation Procedure

  1. Remove any old gasket sealer material from the contact surface.
  2. Apply a continuous line of Three Bond 1217B or equivalent, GM part number 12378521 (Canadian part number 88901148). Standard Seal Diameter: 2.2 to 2.5 mm (0.0866 to 0.0984 in)
  3. Install the water pump and clamp bracket with the 4 bolts and 2 nuts. Tighten: Tighten the bolts to 9.0 N.m (80 lb in).
  4. Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.
  5. Install the wire harness clamp.
  6. Install the water pump pulley with the 4 bolts. Tighten: Tighten the bolts to 26 N.m (19 lb ft).
  7. Install the right engine mounting insulator subassembly. Refer to «Engine Mount Replacement»(ref-341922-S22573497302009102800000) .
  8. Install the generator assembly. Refer to «Generator Replacement (2.4L)»(ref-341923-S15541119442009091700000) .
  9. Install the v-ribbed belt. Refer to «Drive Belt Replacement»(ref-341922-S02680809022009091700000) .
  10. Install the radiator reserve tank assembly. Refer to «Radiator Surge Tank Replacement»(ref-341924-S25613335242009091700000) .
  11. Connect the cable to negative battery terminal.
  12. Add the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  13. Inspect for coolant leaks. Refer to «Cooling System Leak Testing»(ref-341924-S42923381352009091700000) .
  14. Inspect the reservoir tank engine coolant level.
  15. Install the right engine under cover.
  16. Install the left engine under cover.
  1. Disconnect cable from negative battery terminal.
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-341921-S19767900322009091700000) .
  3. Remove the right engine under cover.
  4. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  5. Remove the v-ribbed belt. Refer to «Drive Belt Replacement»(ref-341921-S19643874522009091700000) .
  6. Remove the generator assembly. Refer to «Generator Replacement (1.8L)»(ref-341923-S35233348572009091700000) .
  7. Remove the 5 bolts and water pump assembly from the timing chain cover.
  8. Remove the water pump gasket from the timing chain cover.
  1. Align the protrusion of a new water pump gasket with the cutout in the timing chain cover and install the gasket to the groove of the timing chain cover.
  2. Install the water pump assembly to the timing chain cover with the 5 bolts. Tighten: Bolt A 26 N.m (19 lb ft). Tighten: Bolt B 24 N.m (18 lb ft).
  3. Install the generator assembly. Refer to «Generator Replacement (1.8L)»(ref-341923-S35233348572009091700000) .
  4. Install the v-ribbed belt. Refer to «Drive Belt Replacement»(ref-341921-S19643874522009091700000) .
  5. Connect the cable to negative battery terminal.
  6. Add the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  7. Inspect for coolant leaks. Refer to «Cooling System Leak Testing»(ref-341924-S42923381352009091700000)
  8. Inspect the reservoir tank engine coolant level.
  9. Install the right engine under cover.
  10. Install the engine cover. Refer to «Engine Cover Replacement»(ref-341921-S19767900322009091700000) .
  1. Remove the cap from the radiator surge tank.
  2. Remove the 3 bolts and radiator surge tank assembly.
  1. Install the radiator surge tank assembly with the 3 bolts. Tighten: 7.0 N.m (62 lb in)
  2. Properly fill the cooling system. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000)
  3. Install the radiator surge tank cap.
  1. Remove the radiator assembly. Refer to «Radiator Replacement (2.4L)»(ref-341924-S30291642862009091700000) .
  2. If equipped with air conditioning system, remove the 2 nuts and 2 fans.
  3. Remove the nut and fan.
  4. Remove the auxiliary cooling fan motor, with air conditioning system.
  5. Detach the 4 harness clamps from the fan shroud.
  6. Remove the 2 screws and cooling fan motor insulator.
  7. Remove the 3 screws, and then remove the auxiliary cooling fan motor.
  8. Detach the 3 harness clamps from the fan shroud.
  9. Remove the 3 screws, and then remove the cooling fan motor.
  1. Install the cooling fan motor with the 3 screws. Tighten: 3.9 N.m (35 lb in).
  2. Attach the 3 harness clamps to the fan shroud.
  3. Install the auxiliary cooling fan motor with the 3 screws. Tighten: 3.9 N.m (35 lb in).
  4. Install the cooling fan motor insulator with the 2 screws.
  5. Attach the 4 harness clamps to the fan shroud.
  6. Install auxiliary fan with air conditioning system.
  7. Install the 2 fans with the 2 nuts. Tighten: 6.3 N.m (56 lb in).
  8. Install the fan with the nut. Tighten: 6.3 N.m (56 lb in).
  9. Install the radiator assembly. Refer to «Radiator Replacement (2.4L)»(ref-341924-S30291642862009091700000) .
  1. Remove the radiator assembly. Refer to «Radiator Replacement (1.8L)»(ref-341924-S15432645432009091700000) .
  2. Remove the nut, then remove the fan.
  3. Disconnect the connector and 2 clamps from the fan shroud.
  4. Remove the 3 screws, then remove the cooling fan motor.
  1. Install the cooling fan motor with the 3 screws.
  2. Connect the connector and 2 clamps.
  3. Install the fan with the nut. Tighten: Tighten the nut to 6.3 N.m (56 lb in).
  4. Install the radiator assembly. Refer to «Radiator Replacement (1.8L)»(ref-341924-S15432645432009091700000) .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  2. Disconnect the No. 2 radiator hose.
  3. Remove water inlet.
  4. Remove the 2 nuts and disconnect the water inlet from the cylinder block.
  5. Remove the thermostat and gasket.
  1. Install a new gasket onto the thermostat.
  2. Install the thermostat with the jiggle valve upward.
  3. Install the water inlet with the 2 nuts. Tighten: Tighten the bolts to 9.0 N.m (80 lb in)
  4. Connect the No. 2 radiator hose.
  5. Add the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000)
  6. Inspect for coolant leaks.
  7. Inspect the reservoir tank engine coolant level. Refer to «Cooling System Leak Testing»(ref-341924-S42923381352009091700000) .
  1. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  2. Remove the 2 nuts and water inlet.
  3. Remove the thermostat and gasket.
  4. Remove the gasket from the thermostat.
  1. Install the thermostat.
  2. Install a new gasket on the thermostat.
  3. Install the thermostat to the water inlet with the jiggle valve upward.
  4. Install the water inlet with the 2 nuts. Tighten: 10 N.m (7 lb ft).
  5. Add the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000)
  6. Inspect for coolant leaks. Refer to «Cooling System Leak Testing»(ref-341924-S42923381352009091700000) .
  1. Disconnect cable from negative battery terminal.
  2. Remove the left engine under cover.
  3. Remove the right engine under cover.
  4. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  5. Remove the battery. Refer to «Battery Replacement»(ref-341923-S41849116912009091700000) .
  6. Remove the front bumper assembly. Refer to «Front Bumper Fascia Replacement (Without GT)»(ref-341887-S37447972862009091700000) or «Front Bumper Fascia Replacement (With GT)»(ref-341887-S41451743362009091700000) .
  7. Remove the thermistor assembly.
  8. Disconnect the radiator reservoir tank hose from the radiator assembly.
  9. Disconnect the upper radiator hose from the radiator assembly.
  10. Disconnect the lower radiator hose from the radiator assembly.
  11. Disconnect oil cooler hose.
  12. Remove the 2 bolts and 2 upper radiator supports.
  13. Remove the 2 support cushions from the 2 upper radiator supports.
  14. Remove hood lock assembly. Refer to «Hood Primary and Secondary Latch Replacement»(ref-341880-S31018265892009091700000) .
  15. Separate the water by-pass hose from the 2 clamps.
  16. Disconnect the water by-pass hose from the radiator assembly.
  17. Remove the 2 bolts and hood lock support subassembly.
  18. Disconnect the horn connector.
  19. Remove the 4 bolts and upper radiator support sub-assembly.
  20. Remove the 2 bolts, disengage the 2 claws, and remove the No. 2 fan shroud from the radiator assembly.
  21. Disconnect the cooling fan motor connector and wire harness clamp.
  22. Disconnect the 2 cooling fan motor connectors and wire harness clamp.
  23. Remove the radiator assembly with the fan shroud.
  24. Remove the 2 lower radiator supports.
  25. Disconnect the 2 oil cooler hoses from the radiator.
  26. Disconnect the clamp from the fan shroud.
  27. Remove the 2 bolts and oil cooler hose.
  28. Remove the 2 bolts and fan shroud from the radiator assembly.
  1. Install the fan shroud to the radiator assembly with the 2 bolts. Tighten: Tighten the bolts to 7.0 N.m (62 lb in).
  2. Install the oil cooler hose with the 2 bolts. Tighten: Tighten the bolts to 5.5 N.m (49 lb in)
  3. Connect the clamp to the fan shroud.
  4. Connect the 2 oil cooler hoses to the radiator.
  5. Install radiator assembly.
  6. Install the 2 lower radiator supports.
  7. Install the radiator assembly with the fan shroud.
  8. Connect the cooling fan motor connector, without air conditioning system.
  9. Connect the cooling fan motor connector and wire harness clamp.
  10. Connect the cooling fan motor connector, with air conditioning system.
  11. Connect the 2 cooling fan motor connectors and wire harness clamp.
  12. Engage the 2 claws and install the No. 2 fan shroud to the radiator assembly with the 2 bolts. Tighten: Tighten the bolts to 7.0 N.m (62 lb in).
  13. Install the upper radiator support sub-assembly with the 4 bolts. Tighten: Tighten the bolts to 5.5 N.m (49 lb in).
  14. Connect the horn connector.
  15. Install the hood lock support sub-assembly with the 2 bolts. Tighten: Tighten the bolts to 7.0 N.m (62 lb in).
  16. Install the water by-pass hose with the 2 clamps.
  17. Connect the water by-pass hose to the radiator assembly with the clamp.
  18. Install hood lock assembly. Refer to «Hood Primary and Secondary Latch Replacement»(ref-341880-S31018265892009091700000) .
  19. Install the 2 radiator support cushions to the 2 upper radiator supports.
  20. Install the 2 upper radiator supports with the 2 bolts. Tighten: 19 N.m (14 lb ft).
  21. Connect oil cooler hose.
  22. Connect the lower radiator hose to the radiator assembly with the clamp.
  23. Connect the upper radiator hose to the radiator assembly with the clamp.
  24. Connect the radiator reservoir tank hose to the radiator assembly with the clamp.
  25. Install the thermistor assembly.
  26. Install the battery. Refer to «Battery Replacement»(ref-341923-S41849116912009091700000) .
  27. Connect the cable to negative battery terminal.
  28. Add the engine coolant. «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  29. Inspect for coolant leaks.
  30. Inspect the reservoir tank engine coolant level.
  31. Install front bumper assembly. Refer to «Front Bumper Fascia Replacement (Without GT)»(ref-341887-S37447972862009091700000) or «Front Bumper Fascia Replacement (With GT)»(ref-341887-S41451743362009091700000) .
  32. Vehicle preparation for fog light aiming adjustment with fog light.
  33. Inspect the fog light alignment. Refer to «Fog Lamp Aiming»(ref-341875-S22035079922009091700000) .
  1. Remove the left engine under cover.
  2. Remove the right engine under cover.
  3. Remove the front bumper assembly. Refer to «Front Bumper Fascia Replacement (Without GT)»(ref-341887-S37447972862009091700000) or «Front Bumper Fascia Replacement (With GT)»(ref-341887-S41451743362009091700000) .
  4. Disconnect cable from negative battery terminal.
  5. Drain the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  6. Remove the battery. Refer to «Battery Replacement»(ref-341923-S41849116912009091700000) .
  7. Remove the thermistor assembly.
  8. Disconnect the radiator reservoir tank hose from the radiator assembly.
  9. Disconnect the upper radiator hose from the radiator assembly.
  10. Disconnect the lower radiator hose from the radiator assembly.
  11. Disconnect the oil cooler hose.
  12. Remove the 2 bolts and 2 upper radiator supports.
  13. Remove the 2 support cushions from the 2 upper radiator supports.
  14. Disconnect the hood lock assembly.
  15. Separate the water by-pass hose from the 3 clamps.
  16. Disconnect the water by-pass hose from the radiator assembly.
  17. Remove the 2 bolts and hood lock support subassembly.
  18. Disconnect the horn connector.
  19. Remove the 4 bolts and upper radiator support subassembly.
  20. Remove the 2 bolts, disengage the 2 claws, and remove the No. 2 fan shroud from the radiator assembly.
  21. Disconnect the cooling fan motor connector and wire harness clamp.
  22. Remove the radiator assembly with the fan shroud.
  23. Remove the 2 lower radiator supports.
  24. Remove the oil cooler hose, for the automatic transaxle.
  25. Disconnect the 2 oil cooler hoses from the radiator.
  26. Remove the 2 bolts and oil cooler hose.
  27. Remove the 2 bolts and fan shroud from the radiator assembly.
  1. Install the fan shroud to the radiator assembly with the 2 bolts. Tighten: Tighten the bolts to 7.0 N.m (62 lb in).
  2. Install the oil cooler hose, for the automatic transaxle.
  3. Install the oil cooler hose with the 2 bolts. Tighten: Tighten the bolts to 5.5 N.m (49 lb in).
  4. Connect the 2 oil cooler hoses to the radiator.
  5. Install the 2 lower radiator supports.
  6. Install the radiator assembly with the fan shroud.
  7. Connect the cooling fan motor connector and wire harness clamp.
  8. Engage the 2 claws and install the No. 2 fan shroud to the radiator assembly with the 2 bolts. Tighten: Tighten the bolts to 7.0 N.m (62 lb in).
  9. Install the upper radiator support sub-assembly with the 4 bolts. Tighten: Tighten the bolts to 5.5 N.m (49 lb in).
  10. Connect the horn connector.
  11. Install the hood lock support sub-assembly with the 2 bolts. Tighten: Tighten the bolts to 7.0 N.m (62 lb in).
  12. Install the water by-pass hose with the 3 clamps.
  13. Connect the water by-pass hose to the radiator assembly with the clamp.
  14. Install the hood lock assembly.
  15. Install the 2 radiator support cushions to the 2 upper radiator supports.
  16. Install the 2 upper radiator supports with the 2 bolts. Tighten: Tighten the bolts to 19 N.m (14 lb ft).
  17. Connect oil cooler hose.
  18. Connect the lower radiator hose to the radiator assembly with the clamp.
  19. Connect the upper radiator hose to the radiator assembly with the clamp.
  20. Connect the radiator reservoir tank hose to the radiator assembly with the clamp.
  21. Install the thermistor assembly.
  22. Install the battery. Refer to «Battery Replacement»(ref-341923-S41849116912009091700000) .
  23. Connect the cable to negative battery terminal.
  24. Add the engine coolant. Refer to «Cooling System Draining and Filling»(ref-341924-S10966194692009091700000) .
  25. Inspect for coolant leaks.
  26. Inspect the reservoir tank engine coolant level.
  27. Install the front bumper assembly. Refer to «Front Bumper Fascia Replacement (Without GT)»(ref-341887-S37447972862009091700000) or «Front Bumper Fascia Replacement (With GT)»(ref-341887-S41451743362009091700000) .
  28. Adjust fog light alignment. Refer to «Fog Lamp Aiming»(ref-341875-S22035079922009091700000) .
  29. Install left engine under cover.
  30. Install right engine under cover.

Scheme 3

Scheme 3: Single Fan - 1.8L (RPO-LAY)
Scheme 3: Single Fan - 1.8L (RPO-LAY)

The engine cooling fan system consists of an electric cooling fan, a fan relay, and a fan control module (FCM). The fan 1 relay provides power to the FCM. The FCM energizes the fan and controls fan speed according to instructions received from the powertrain control module (PCM). The PCM determines the desired fan speed according to input from various sensors and systems. The cooling fan and fan relay receive battery positive voltage from the underhood fuse block. The ground path is provided at G102.

Sensor Inputs to the PCMCooling Fan Control Module Response - Fan Speed
Engine Coolant Temperature IncreasesIncreases
Engine Coolant Temperature DecreasesDecreases
Engine Speed IncreasesIncreases
Engine Speed DecreasesDecreases
Vehicle Speed IncreasesDecreases
Vehicle Speed DecreasesIncreases
A/C Refrigerant Pressure IncreasesIncreases
A/C Refrigerant Pressure DecreasesDecreases

Variable Speed Fan Operation

Scheme 4

Scheme 4: Dual Fans - 2.4L (RPO-LAX)
Scheme 4: Dual Fans - 2.4L (RPO-LAX)

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a series parallel (S/P) configuration that allows the powertrain control module (PCM) to operate both fans together at low or high speeds, depending on cooling requirements. The cooling fans and fan relays receive battery positive voltage from the underhood fuse block. The ground path is provided at G102.

In low speed operation, the PCM applies ground to the coil side of the low speed fan relay 3. This energizes the coil and applies voltage directly to the auxiliary cooling fan through the switch side of the low relay 3. The fan is connected in series to the main cooling fan through the de-energized S/P fan control relay 2. The series circuit operates both fans at low speed.

In high speed operation, the PCM applies a ground to the coil side of the low speed fan relay 3, the fan control relay 2, and the high speed fan relay 1. When energized, the high speed fan relay 1 applies voltage directly to the main cooling fan through the switch side of the relay. Simultaneously, the low speed fan relay 3 and the fan control relay 2 provide ignition voltage and a direct path to ground for the auxiliary cooling fan. With both fans connected in a parallel circuit, each fan receives full voltage and operates at high speed.

The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly.

More articles — Engine Cooling System