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Cooling System: Component Locations Saab 9-4X I

Cooling System (Mechanical) 56 illustrations ~2032 words

Special Tools

Illustration Tool Number/Description EN 46104 J 46104 Water Pump Pulley Holding Tool GE 47716 Vac N Fill Coolant Refill Tool EN 24460-A J 24460-01 Cooling System Pressure Tester GE 24731 J 24731 Tempilstick GE 26568 J 26568 Coolant and Battery Fluid Tester EN 28410 J 28410 Gasket Remover (Aluminum Components DT 41623-B J 41623-B Quick Connect Tool BO 38185 J 38185 Hose Clamp Pliers GE 47622 Hose Clamp Pliers BO 38778 J 38778 Door Trim Clip Remover GE 42401-A J 42401 Radiator Cap and Surge Tank Test Adapter EL 43244 J 43244 Relay Puller Pliers

Scheme 17

Scheme 17: Special Tools
Scheme 17: Special Tools

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

J 24731 Tempil Stick

For equivalent regional tools, refer to SPECIAL TOOLS

Use one of the following procedures in testing for a malfunctioning thermostat.

  1. GE-24460-A Cooling System Pressure Tester
  2. GE-42401-A Radiator Cap/Surge Tank Test Adapter Kit

For equivalent regional tools, refer to SPECIAL TOOLS

Scheme 26

Scheme 26: Pressure Cap Testing
Scheme 26: Pressure Cap Testing
  1. WARNING: Do not remove the radiator cap or surge tank cap when the engine is hot. Risk of scalding. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the pressure cap.
  2. Wash the pressure cap sealing surface with water.
  3. Use the GE-24460-01 , Cooling System Pressure Tester (1) with GE-42401-A , Radiator Cap/Surge Tank Test Adapter Kit (2) in order to test the pressure cap.
  4. Test the pressure cap for the following conditions: Pressure release when the GE-24460-01 Cooling System Pressure Tester exceeds the pressure rating of the pressure cap. Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
  5. Replace the pressure cap under the following conditions: The pressure cap does not release pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

Special Tools

  1. GE-24460-01 Cooling System Pressure Tester
  2. GE-42401-A Radiator Cap/Surge Tank Test Adapter

For equivalent regional tools, refer to SPECIAL TOOLS

Scheme 27

Scheme 27
Scheme 27
  1. WARNING: Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders, and the person removing the cap. Serious bodily injury may result. Flammable antifreeze, such as alcohol, is not recommended for use at any time. Flammable antifreeze could cause a serious fire. WARNING: In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon. Remove the pressure cap.
  2. Test the operation of the pressure cap. Refer to «PRESSURE CAP TESTING»(ref-652237-S18409386452014082300000) .
  3. Wash the pressure cap mating surface with water.
  4. Use the GE-24460-01 Cooling System Pressure Tester with the GE-42401-3 Radiator Cap/Surge Tank Test Adapter and GE-42401-2 Radiator Cap/Surge Tank Test Adapter in order to apply pressure to the cooling system. Do not exceed the pressure cap rating.
  5. The cooling system should hold the rated pressure for at least 2 minutes. Observe the gauge for any pressure loss.
  6. Repair any leaks as required.
Object code - IDDescriptionConditionVariantModel yearCorrectionTerminalTime (hrs)
26110-01Radiator2011012.2
26110-02Radiator2011032.2
26118-01Fastener2011068.5
26122-01Upper tank2011010.3
26123-01Level sensor, coolant2011010.6
26129-01Hose or pipe, ventilation2011010.3
26130-01Oil cooler2011012.8
26134-01Oil pipe, hose2011010.1
26141-01Hose, upperEngine Oil Cooler Outlet Hose Replacement2011010.9
26141-02Hose, upperRadiator Surge Tank Outlet Hose Replacement2011010.2
26142-01Hose, lowerRadiator Surge Tank Inlet Hose Replacement2011010.2
26142-02Hose, lowerRadiator Outlet Pipe Replacement201101081.9
26144-01Hose, exp. vessel - pump2011010.2
26146-01Water hose, oil cooler2011010.9
26147-01Joining pipeA28NER201101021.2
26154-01Coolant pipe turbo, lower2011010.6
26155-01Coolant pipe turbo, upper2011011.5
26210-01Coolant pump2011011.3
26219-01Pulley2011010.9
26221-01Thermostat housing2011010.8
26223-01Thermostat2011010.8
26224-01Coolant temperature sensor201101020.0
26227-01Circulation pump2011010.9
26231-01HoseRadiator Inlet Hose Replacement2011010.6
26231-02HoseRadiator Outlet Hose Replacement2011010.6
26251-01Fan motor comp.2011012.0
26271-01Coolant Heater2011010.2
26272-01Connecting cable2011010.2

Location (pos)

  1. 01 - Front
  2. 02 - Rear
  3. 03 - Left
  4. 04 - Right Hand
  5. 05 - All
  6. 06 - Upper
  7. 07 - Center
  8. 08 - Lower
  9. 09 - Service Information
  1. GE-26568 Coolant and Battery Fluid Tester
  2. GE-42401-A Radiator Cap and Surge Tank Test Adapter
  3. GE-47716 Vac N Fill Coolant Refill Tool

For equivalent regional tools, refer to SPECIAL TOOLS

GE-26568 Coolant and Battery Fluid Tester

For equivalent regional tools, refer to SPECIAL TOOLS

Scheme 28

Scheme 28: Draining Procedure
Scheme 28: Draining Procedure
  1. WARNING: Do not remove the radiator cap or surge tank cap when the engine is hot. Risk of scalding. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the coolant pressure cap from the radiator surge tank.
  2. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  3. Remove the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000)
  4. Place a drain pan under the drain cock.
  5. Loosen the radiator drain cock (1).
  6. Drain the cooling system.
  7. Lower the vehicle.
  8. Inspect the coolant.
  9. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «FLUSHING»(ref-652237-S36705839922014082300000) .

Scheme 29

Scheme 29: Filling Procedure
Scheme 29: Filling Procedure

Scheme 30

Scheme 30
Scheme 30
  1. WARNING: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage. Raise and support the vehicle.
  2. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) Tighten the radiator's emptying valve (1) with 2 Nm (18 lb in) .
  3. Install the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000)
  4. Lower the vehicle.
  5. NOTE: Use a 50/50 mixture of DEX-COOL antifreeze and clean drinkable water. Slowly fill the radiator with a 50/50 coolant mixture until the coolant level reaches the base of the radiator surge tank. Refer to «APPROXIMATE FLUID CAPACITIES»(ref-652230-S15350669442014082300000) .
  6. Allow 30 seconds for the coolant level to stabilize and continue to fill the coolant filler neck until the level stabilizes for at least 2 minutes.
  7. Start the engine and allow to the engine to idle in PARK or NEUTRAL with the parking brake engaged.
  8. Slowly fill the coolant mixture until the level stabilizes at the base of the radiator surge tank.
  9. Install the coolant pressure cap.
  10. Raise the engine RPM to 2500 RPM for 30-40 seconds.
  11. Turn OFF the engine.
  12. Allow the engine to cool, remove coolant fill cap and repeat steps 4 - 10 until the coolant level has completely stabilized within the radiator surge tank.
  13. Inspect the concentration of the coolant mixture using GE-26568 Coolant and Battery Fluid Tester.
  14. Inspect and if necessary, fill the coolant reservoir bottle as necessary.
  15. Rinse away any excess coolant from the engine and the engine compartment.
  16. Inspect the cooling system for leaks.
  17. Top off the radiator surge tank if necessary.

GE-26568 Coolant and Battery Fluid Tester

For equivalent regional tools, refer to SPECIAL TOOLS

Scheme 31

Scheme 31: Draining Procedure
Scheme 31: Draining Procedure
  1. WARNING: Do not remove the radiator cap or surge tank cap when the engine is hot. Risk of scalding. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the coolant pressure cap from the radiator surge tank.
  2. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  3. Remove the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000)
  4. Place a drain pan under the drain cock.
  5. Loosen the radiator drain cock (1).
  6. Drain the cooling system.
  7. Lower the vehicle.
  8. Inspect the coolant.
  9. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «FLUSHING»(ref-652237-S36705839922014082300000) .

Scheme 32

Scheme 32: Filling Procedure
Scheme 32: Filling Procedure

Scheme 33

Scheme 33
Scheme 33
  1. WARNING: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage. Raise and support the vehicle.
  2. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Tighten the radiator's emptying valve (1) with 2 Nm (18 lb in) .
  3. Install the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000)
  4. Lower the vehicle.
  5. NOTE: Use a 50/50 mixture of DEX-COOL antifreeze and clean drinkable water. Slowly fill the radiator with a 50/50 coolant mixture until the coolant level reaches the base of the radiator surge tank. Refer to «APPROXIMATE FLUID CAPACITIES»(ref-652230-S15350669442014082300000) .
  6. Allow 30 seconds for the coolant level to stabilize and continue to fill the coolant filler neck until the level stabilizes for at least 2 minutes.
  7. Start the engine and allow to the engine to idle in PARK or NEUTRAL with the parking brake engaged.
  8. Slowly fill the coolant mixture until the level stabilizes at the base of the radiator surge tank.
  9. Install the coolant pressure cap.
  10. Raise the engine RPM to 2500 RPM for 30-40 seconds.
  11. Turn OFF the engine.
  12. Allow the engine to cool, remove coolant fill cap and repeat steps 4 - 10 until the coolant level has completely stabilized within the radiator surge tank.
  13. Inspect the concentration of the coolant mixture using GE-26568 Coolant and Battery Fluid Tester.
  14. Inspect and if necessary, fill the coolant reservoir bottle as necessary.
  15. Rinse away any excess coolant from the engine and the engine compartment.
  16. Inspect the cooling system for leaks.
  17. Top off the radiator surge tank if necessary.

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to SPECIAL TOOLS

Scheme 34

Scheme 34: Removal Procedure
Scheme 34: Removal Procedure

Scheme 35

Scheme 35
Scheme 35
  1. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000) .
  3. Disengage tension on the radiator inlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  4. Remove the radiator inlet hose (2) from the radiator.
  5. Unclip radiator inlet hose connector (1) and remove the radiator inlet hose (2) from the engine.
  6. Remove the radiator inlet hose from the vehicle.

Scheme 36

Scheme 36: Installation Procedure
Scheme 36: Installation Procedure

Scheme 37

Scheme 37
Scheme 37
  1. Install radiator inlet hose to the vehicle.
  2. NOTE: Lubricate the inside diameters of the hose with clean coolant prior to installation. Clip the radiator inlet hose (2) to the engine.
  3. Install the radiator inlet hose (2) to the radiator.
  4. Engage tension on the radiator inlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  5. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000) .
  6. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .

Scheme 38

Scheme 38: Radiator Outlet Hose Replacement (LAU)
Scheme 38: Radiator Outlet Hose Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE Remove the auxiliary water pump inlet hose. Refer to AUXILIARY WATER PUMP INLET HOSE REPLACEMENT (LAU)
1Radiator Outlet Hose Clamp Procedure Disengage tension on the radiator outlet hose clamp using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS
2Radiator Outlet Hose

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to SPECIAL TOOLS

Scheme 39

Scheme 39: Removal Procedure
Scheme 39: Removal Procedure

Scheme 40

Scheme 40
Scheme 40
  1. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  3. Remove the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000) .
  4. Disengage tension on the radiator outlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  5. Remove the radiator outlet hose (2) from the radiator.
  6. Disengage tension on the radiator outlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  7. Remove the radiator outlet hose (2) from the engine.
  8. Remove the radiator outlet hose from the vehicle.

Scheme 41

Scheme 41: Installation Procedure
Scheme 41: Installation Procedure

Scheme 42

Scheme 42
Scheme 42
  1. Install radiator outlet hose to the vehicle.
  2. NOTE: Lubricate the inside diameters of the hose with clean coolant prior to installation. Install the radiator outlet hose (2) to the engine.
  3. Engage tension on the radiator outlet hose clamp (1) at the engine using BO-38185 Hose Clamp Pliers.
  4. Install the radiator outlet hose (2) to the radiator.
  5. Engage tension on the radiator outlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers.
  6. Install the radiator air lower deflector. Refer to «RADIATOR AIR LOWER DEFLECTOR REPLACEMENT»(ref-652246-S08001852322014082300000) .
  7. Lower the vehicle.
  8. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) or «COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .

Scheme 43

Scheme 43: Radiator Outlet Pipe Replacement (LAU)
Scheme 43: Radiator Outlet Pipe Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the coolant system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the battery tray support. Refer to BATTERY TRAY SUPPORT REPLACEMENT . Remove the engine oil cooler outlet hose. Refer to ENGINE OIL COOLER OUTLET HOSE REPLACEMENT (LAU) . Remove the radiator outlet hose. Refer to RADIATOR OUTLET HOSE REPLACEMENT (LAU) or RADIATOR OUTLET HOSE REPLACEMENT (LF1) . Remove the transmission heat shield. Refer to TRANSMISSION HEAT SHIELD REPLACEMENT (LAU) .
1Radiator Outlet Pipe Retainer Bolt Refer to CAUTION: RETAINER Tighten 10 Nm (7 lb ft)
2Seal
3Radiator Outlet Pipe Bolt Tighten 9 Nm (6 lb ft)
4Radiator Outlet Pipe

Scheme 44

Scheme 44: Charge Air Cooler Duct Quick-Connect Fitting Disconnection
Scheme 44: Charge Air Cooler Duct Quick-Connect Fitting Disconnection

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47
  1. Push quick connect coupling (1) in the direction shown in the picture to unlock the secondary engagement of the quick connect retaining clip.
  2. Place a screw driver (1) under the quick connect retaining clip.
  3. Push the screw driver (1) downwards to open the quick connect retaining clip.
  4. With the quick connect retaining clip (1) opened the mating tube can be disconnected.

Scheme 48

Scheme 48: Charge Air Cooler Replacement (LAU)
Scheme 48: Charge Air Cooler Replacement (LAU)
CalloutComponent Name
Preliminary Procedure Remove the air conditioner condenser. Refer to AIR CONDITIONING CONDENSER REPLACEMENT (LF1) or AIR CONDITIONING CONDENSER REPLACEMENT (LAU) . Remove the charge air cooler inlet duct. Refer to CHARGE AIR COOLER INLET DUCT REPLACEMENT . Remove the charge air cooler outlet duct. Refer to CHARGE AIR COOLER OUTLET DUCT REPLACEMENT .
1Charge Air Cooler Bolt (Qty: 2) Refer to CAUTION: RETAINER Tighten 9 N m (80 lb in)
2Charge Air Cooler

Scheme 49

Scheme 49: Auxiliary Water Pump Inlet Hose Replacement (LAU)
Scheme 49: Auxiliary Water Pump Inlet Hose Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE
1Auxiliary Water Pump Inlet Hose Clamps (Qty 2) Procedure Disengage tension on the auxiliary water pump inlet hose clamps using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS
2Auxiliary Water Pump Inlet Hose

Scheme 50

Scheme 50: Auxiliary Water Pump Outlet Upper Hose Replacement (LAU)
Scheme 50: Auxiliary Water Pump Outlet Upper Hose Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE Remove the secondary air injection pump. Refer to SECONDARY AIR INJECTION PUMP REPLACEMENT
1Auxiliary Water Pump Outlet Upper Hose Clamps (Qty 2) Procedure Disengage tension on the auxiliary water pump outlet upper hose clamps using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS
2Auxiliary Water Pump Outlet Upper Hose

Scheme 51

Scheme 51: Auxiliary Water Pump Outlet Hose Replacement (LAU)
Scheme 51: Auxiliary Water Pump Outlet Hose Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE
1Auxiliary Water Pump Outlet Hose Clamps (Qty 2) Procedure Disengage tension on the auxiliary water pump outlet hose clamps using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS
2Auxiliary Water Pump Outlet Hose

Scheme 52

Scheme 52: Engine Oil Cooler Outlet Hose Replacement (LAU)
Scheme 52: Engine Oil Cooler Outlet Hose Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE Reposition the auxiliary water pump. Refer to AUXILIARY WATER PUMP REPLACEMENT (LAU) Remove the secondary air injection pump. Refer to SECONDARY AIR INJECTION PUMP REPLACEMENT
1Engine Oil Cooler Outlet Hose Clamps (Qty 2) Procedure Disengage tension on the engine oil cooler outlet hose clamps using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS
2Engine Oil Cooler Outlet Hose

Scheme 53

Scheme 53: Engine Oil Cooler Hose/Pipe Replacement (LAU)
Scheme 53: Engine Oil Cooler Hose/Pipe Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE Reposition the auxiliary water pump. Refer to AUXILIARY WATER PUMP REPLACEMENT (LAU)
1Engine Oil Cooler Hose Clamps (Qty 2) Procedure Disengage tension on the engine oil cooler hose clamps using BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS
2Engine Oil Cooler Hose

Scheme 54

Scheme 54: Engine Coolant Fan Replacement (LAU)
Scheme 54: Engine Coolant Fan Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Remove the cooling fan shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT (LAU) or COOLING FAN AND SHROUD REPLACEMENT (LF1) .
1Cooling Fan Retainer (Qty: 3) Refer to CAUTION: RETAINER Tighten 7 Nm (62 lb in)
2Cooling Fan NOTE: Disconnect electrical connector from fan.
NOTE
Disconnect electrical connector from fan.

Scheme 55

Scheme 55: Engine Coolant Fan Motor Replacement (LF1)
Scheme 55: Engine Coolant Fan Motor Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Remove the cooling fan shroud. Refer to COOLING FAN AND SHROUD REPLACEMENT (LAU) or COOLING FAN AND SHROUD REPLACEMENT (LF1)
1Cooling Fan Retainer
2Cooling Fan

Scheme 56

Scheme 56: Engine Coolant Fan Motor Replacement (LF1)
Scheme 56: Engine Coolant Fan Motor Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Remove the cooling fan. Refer to ENGINE COOLANT FAN REPLACEMENT (LAU) or ENGINE COOLANT FAN MOTOR REPLACEMENT (LF1)
1Cooling Fan Motor Bolts (Qty 3) Refer to CAUTION: RETAINER Tighten 7 Nm (62 lb in)
2Cooling Fan Motor Procedure Unclip cooling fan motor wiring harness from cooling fan shroud.

Scheme 57

Scheme 57: Cooling Fan and Shroud Replacement (LAU)
Scheme 57: Cooling Fan and Shroud Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Reposition radiator forward. Refer to RADIATOR REPLACEMENT (LAU) or RADIATOR REPLACEMENT (LF1) .
1Cooling Fan Shroud Bolt (Qty: 2) Refer to CAUTION: RETAINER Tighten 8 Nm (70 lb in)
2Cooling Fan Shroud Procedure Disconnect cooling fan motor wiring harness.

Scheme 58

Scheme 58: Cooling Fan and Shroud Replacement (LF1)
Scheme 58: Cooling Fan and Shroud Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Reposition radiator forward. Refer to RADIATOR REPLACEMENT (LAU) or RADIATOR REPLACEMENT (LF1) .
1Cooling Fan Shroud Bolts (Qty 2) Refer to CAUTION: RETAINER Tighten 8 Nm (70 lb in)
2Cooling Fan Shroud Procedure Disconnect cooling fan motor wiring harness. Disconnect cooling fan resistor wiring harness.

Scheme 59

Scheme 59: Engine Coolant Fan Resistor Replacement - Right Side (LF1)
Scheme 59: Engine Coolant Fan Resistor Replacement - Right Side (LF1)
CalloutComponent Name
Preliminary Procedures Disconnect the engine cooling fan resistor electrical connector.
1Engine Cooling Fan Resistor Fasteners Refer to CAUTION: RETAINER . Tighten 5.4 Nm (48 lb in)
2Engine Cooling Fan Resistor

Scheme 60

Scheme 60: Engine Coolant Fan Resistor Replacement - Left Side (LF1)
Scheme 60: Engine Coolant Fan Resistor Replacement - Left Side (LF1)
CalloutComponent Name
Preliminary Procedures Disconnect the engine cooling fan resistor electrical connector.
1Engine Cooling Fan Resistor Fasteners Refer to CAUTION: RETAINER . Tighten 5.4 Nm (48 lb in)
2Engine Cooling Fan Resistor

Scheme 61

Scheme 61: Engine Coolant Level Indicator Module Replacement
Scheme 61: Engine Coolant Level Indicator Module Replacement
CalloutComponent Name
Preliminary Procedures Remove radiator surge tank. Refer to RADIATOR SURGE TANK REPLACEMENT (LAU) or RADIATOR SURGE TANK REPLACEMENT (LF1)
1Engine Coolant Level Indicator Module NOTE: Unplug electrical connector from engine coolant level indicator module.
NOTE
Unplug electrical connector from engine coolant level indicator module.

Scheme 62

Scheme 62: Turbocharger Coolant Feed Pipe Replacement (LAU)
Scheme 62: Turbocharger Coolant Feed Pipe Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) Reposition the auxiliary water pump. Refer to AUXILIARY WATER PUMP REPLACEMENT (LAU) . Remove the secondary air injection pump. Refer to SECONDARY AIR INJECTION PUMP REPLACEMENT . Remove the starter. Refer to STARTER REPLACEMENT (LAU) or STARTER REPLACEMENT (LF1) .
1Banjo Bolt Refer to CAUTION: RETAINER Tighten 35 Nm (26 lb ft)
2Turbocharger Outlet Hose
3Banjo Bolt Tighten 35 Nm (26 lb ft)
4Turbocharger Coolant Feed Bracket Bolt Tighten 10 Nm (7 lb ft)
5Turbocharger Coolant Feed Pipe

Scheme 63

Scheme 63: Turbocharger Coolant Return Pipe Replacement (LAU)
Scheme 63: Turbocharger Coolant Return Pipe Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the radiator surge tank engine hose. Refer to RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT (LAU) .
1Radiator Surge Tank Engine Hose
2Banjo Bolt Refer to CAUTION: RETAINER Tighten 35 Nm (26 lb ft)
3Banjo Bolt Tighten 35 Nm (26 lb ft)
4Turbocharger Coolant Return Pipe

Scheme 64

Scheme 64: Engine Coolant Thermostat Housing Replacement (LF1)
Scheme 64: Engine Coolant Thermostat Housing Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the intake manifold cover. Refer to INTAKE MANIFOLD COVER REPLACEMENT . Remove the fuel pipe shield. Refer to FUEL PIPE SHIELD REPLACEMENT
1Heater Outlet Hose
2Heater Inlet Hose
3Surge Tank Hose
4Radiator Outlet Hose
5Bolt (Qty: 3) Refer to CAUTION: RETAINER Tighten 10 Nm (88 lb in)
6Engine Cooling Thermostat Housing Procedure Clean the engine block and thermostat gasket surfaces. Replace the gasket and any damaged hoses.

Scheme 65

Scheme 65: Engine Coolant Thermostat Housing Replacement (LAU)
Scheme 65: Engine Coolant Thermostat Housing Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the turbocharger. Refer to TURBOCHARGER REPLACEMENT .
1Engine Coolant Thermostat Housing Bolt Refer to CAUTION: RETAINER Tighten 10 Nm (88 lb in)
2Engine Coolant Thermostat Housing Gasket NOTE: Replace the gasket with a NEW gasket.
3Engine Coolant Thermostat
4Engine Coolant Thermostat Housing
NOTE
Replace the gasket with a NEW gasket.

Scheme 66

Scheme 66: Engine Coolant Thermostat Replacement (LF1)
Scheme 66: Engine Coolant Thermostat Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Remove the engine cooling thermostat housing. Refer to ENGINE COOLANT THERMOSTAT HOUSING REPLACEMENT (LF1) or ENGINE COOLANT THERMOSTAT HOUSING REPLACEMENT (LAU) .
1Bolt (Qty: 3) Refer to CAUTION: RETAINER Tighten 10 Nm (88 lb in)
2Engine Cooling Thermostat Gasket
3Engine Cooling Thermostat Procedure Clean the engine block and the thermostat gasket surfaces. Replace the gasket and any worn hoses.

Scheme 67

Scheme 67: Engine Coolant Thermostat Replacement (LAU)
Scheme 67: Engine Coolant Thermostat Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the turbocharger. Refer to TURBOCHARGER REPLACEMENT .
1Engine Coolant Thermostat Housing Bolt Refer to CAUTION: RETAINER Tighten 10 Nm (88 lb in)
2Engine Coolant Thermostat Housing Gasket NOTE: Replace the gasket with a NEW gasket.
3Engine Coolant Thermostat
4Engine Coolant Thermostat Housing
NOTE
Replace the gasket with a NEW gasket.

Scheme 68

Scheme 68: Engine Coolant Air Bleed Pipe Replacement (LAU)
Scheme 68: Engine Coolant Air Bleed Pipe Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to INTAKE MANIFOLD COVER REPLACEMENT .
1Engine Coolant Air Bleed Pipe Retainer Bolt (Qty: 2) Refer to CAUTION: RETAINER Tighten 10 Nm (7 lb ft)
2Engine Coolant Air Bleed Pipe Retainer Bolt Tighten 10 Nm (7 lb ft)
3Engine Coolant Air Bleed Nut Tighten 10 Nm (7 lb ft)
4Radiator Surge Tank Inlet Hose
5Engine Coolant Air Bleed Hose
6Engine Coolant Air Bleed Pipe

Scheme 69

Scheme 69: Engine Coolant Air Bleed Pipe Replacement (LF1)
Scheme 69: Engine Coolant Air Bleed Pipe Replacement (LF1)
CalloutComponent Name
Preliminary Procedures Partially drain the coolant system. Remove the intake manifold cover. Refer to INTAKE MANIFOLD COVER REPLACEMENT . Reposition the power steering fluid reservoir. Refer to POWER STEERING FLUID RESERVOIR REPLACEMENT (LF1) Remove the air cleaner outlet duct. Refer to AIR CLEANER OUTLET DUCT REPLACEMENT (LAU) or AIR CLEANER OUTLET DUCT REPLACEMENT (LF1) .
1Engine Coolant Air Bleed Pipe Bolt Refer to CAUTION: RETAINER Tighten 10 Nm (88 lb in)
2Retainer
3Engine Coolant Air Bleed Pipe

Scheme 70

Scheme 70: Water Outlet Replacement (LAU)
Scheme 70: Water Outlet Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the right engine mount bracket. Refer to ENGINE MOUNT REPLACEMENT - RIGHT SIDE Remove the radiator inlet hose from the water outlet. Refer to RADIATOR INLET HOSE REPLACEMENT (LAU) or RADIATOR INLET HOSE REPLACEMENT (LF1) Remove the engine coolant air bleed pipe from the water outlet. See ENGINE COOLANT AIR BLEED PIPE REPLACEMENT (LAU) or ENGINE COOLANT AIR BLEED PIPE REPLACEMENT (LF1)
1Bolt (Qty: 2) Refer to CAUTION: RETAINER . Tighten 10 Nm (88 lb in)
2Water Outlet
3Seal NOTE: Clean the surfaces and replace the seal.
NOTE
Clean the surfaces and replace the seal.

Scheme 71

Scheme 71: Heater Outlet Pipe Replacement (LAU)
Scheme 71: Heater Outlet Pipe Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (LAU) . Remove the transmission heat shield. Refer to TRANSMISSION HEAT SHIELD REPLACEMENT (LAU) . Remove the radiator surge tank outlet hose. Refer to RADIATOR SURGE TANK OUTLET HOSE REPLACEMENT (LAU) or RADIATOR SURGE TANK OUTLET HOSE REPLACEMENT (LF1) . Remove the heater outlet hose. Refer to HEATER OUTLET HOSE REPLACEMENT (LF1) or HEATER OUTLET HOSE REPLACEMENT (LAU) .
1Radiator Surge Tank Outlet Hose
2Heater Outlet Hose
3Heater Outlet Pipe Retainer Bolt Refer to CAUTION: RETAINER Tighten 10 Nm (7 lb ft)
4Seal
5Heater Hose Outlet Pipe

Scheme 72

Scheme 72: Water Pump Replacement (LAU)
Scheme 72: Water Pump Replacement (LAU)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (GE 47716) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LAU) or COOLING SYSTEM DRAINING AND FILLING (STATIC FILL LF1) . Remove the drive belt. Refer to DRIVE BELT REPLACEMENT . Clean gasket surfaces and replace water pump seal and gasket.
1Water Pump Bolt (Qty: 6) Refer to CAUTION: RETAINER Tighten 10 Nm (88 lb in) Correction See WATER PUMP INSTALLATION for tightening sequence.
2Water Pump Gasket
3Water Pump Seal
4Water Pump Correction Clean the water pump's connection surfaces. Fit a NEW water pump gasket

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