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Cooling System: Removal & Installation Saab 9-5 II

Cooling System (Mechanical) 61 illustrations ~2927 words

Removal Procedure

WARNINGWith 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.

Scheme 2

Scheme 2
Scheme 2
  1. Turn the ignition OFF.
  2. Remove the fuel injector sight shield. Refer to «UPPER ENGINE COVER REMOVAL»(ref-653637-S35661870322014090100000) .
  3. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  4. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  5. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) .
  6. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  7. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (6-CYL)»(ref-653660-S06653600572014090100000) .
  8. Remove the charge air cooler outlet air tube. Refer to «CHARGE AIR COOLER OUTLET AIR TUBE REPLACEMENT»(ref-653660-S26275936972014090100000) .
  9. Remove both radiator inlet hose retainers.
  10. Remove the radiator inlet hose (1).

Scheme 3

Scheme 3: Installation Procedure
Scheme 3: Installation Procedure
  1. Install the radiator inlet hose (1).
  2. Install both radiator inlet hose retainers.
  3. Install the charge air cooler outlet air tube. Refer to «CHARGE AIR COOLER OUTLET AIR TUBE REPLACEMENT»(ref-653660-S26275936972014090100000) .
  4. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (6-CYL)»(ref-653660-S06653600572014090100000) .
  5. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  6. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  7. Connect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  8. Install the fuel injector sight shield. Refer to «UPPER ENGINE COVER REMOVAL»(ref-653637-S35661870322014090100000) .
  9. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) .

Scheme 4

Scheme 4: Radiator Inlet Hose Replacement (LHU/A20NFT)
Scheme 4: Radiator Inlet Hose Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Remove the engine sight shield. Refer to ENGINE SIGHT SHIELD REPLACEMENT . Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) .
1Engine Coolant Air Bleed Hose Quick Disconnect. Procedure Release the clip and remove the engine coolant air bleed hose from the radiator inlet hose
2Radiator Inlet Hose Clamps (Qty 2). Procedure Reduce tension on the radiator inlet hose clamps using the BO-38185 Hose Clamp Pliers. Special Tools BO-38185 Hose Clamp Pliers
3Radiator Inlet Hose

Scheme 5

Scheme 5: Radiator Outlet Hose Replacement (LAU/A28NER)
Scheme 5: Radiator Outlet Hose Replacement (LAU/A28NER)
CalloutComponent Name
WARNING: With 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. Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT . Remove the air cleaner outlet duct. Refer to AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL) . Remove the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement (LAU/A28NER) .
1Radiator Outlet Hose Retainer Procedure Remove both retainers.
WARNING
With 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.

Scheme 6

Scheme 6: Radiator Outlet Hose Replacement (LHU/A20NFT)
Scheme 6: Radiator Outlet Hose Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the charge cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR)
1Radiator Outlet Hose Clamps (Qty 3) Procedure Reposition the radiator outlet hose clamp using the BO-38185 Hose Clamp Pliers Special Tools BO-38185 Hose Clamp Pliers
2Radiator Outlet Hose

Scheme 7

Scheme 7: Radiator Outlet Pipe Replacement
Scheme 7: Radiator Outlet Pipe Replacement
CalloutComponent Name
Preliminary Procedure Remove the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LAU/A28NER) or Engine Coolant Thermostat Replacement (LHU/A20NFT) .
1Radiator Outlet Pipe Procedure Pull the radiator outlet pipe out from the water pump.

Scheme 8

Scheme 8: Repair Procedure
Scheme 8: Repair Procedure

Scheme 9

Scheme 9
Scheme 9
  1. Pressure test the cooling system. Refer to «COOLING SYSTEM LEAK TESTING»(ref-653648-S35042258202014090100000) .
  2. NOTE: If the radiator is leaky, replace it. Refer to «RADIATOR REPLACEMENT (LAU/A28NER)»(ref-653648-S00016283872014090100000) or «RADIATOR REPLACEMENT (LHU/A20NFT)»(ref-653648-S42638314672014090100000) . Grind the fracture surface (1) with a proper tool.
  3. Drill a persistent hole in center of the fracture surface, using a 6 mm (0.24 in) drill.
  4. NOTE: The bolt should not be longer than 25 mm (0.98 in). Install the new radiator mounting pin (2). Install the nut (3) Install the radiator mounting pin (2) with the bolt (1)

Scheme 10

Scheme 10: Engine Coolant Fan Resistor Bracket Repair
Scheme 10: Engine Coolant Fan Resistor Bracket Repair
CalloutComponent Name
Preliminary Procedure Remove the engine coolant fan shroud. Refer to ENGINE COOLANT FAN SHROUD REPLACEMENT (LAU/A28NER) ENGINE COOLANT FAN SHROUD REPLACEMENT (LHU/A20NFT) .
1Engine Coolant Fan Resistor Mount Bolt
2Engine Coolant Fan Resistor Mount
3Engine Coolant Fan Resistor Mount Fastener

Scheme 11

Scheme 11: Charge Air Cooler Inlet Hose Replacement (LAU/A28NER)
Scheme 11: Charge Air Cooler Inlet Hose Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Turn the ignition OFF. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION . Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT . Remove the engine control module from the battery tray. Refer to ENGINE CONTROL MODULE REPLACEMENT (V6) .
1Charge Air Cooler Inlet Hose Fastener Refer to FASTENER CAUTION . Tighten 4 Nm (36 lb in)
2Charge Air Cooler Inlet Hose Fastener Tighten 4 Nm (36 lb in)
3Charge Air Cooler Inlet Hose

Scheme 12

Scheme 12: Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR)
Scheme 12: Charge Air Cooler Inlet Hose Replacement (LBY/A20DTR)
CalloutComponent Name
Preliminary Procedure Remove the engine shield. Refer to ENGINE SHIELD REPLACEMENT
1Charge Air Cooler Inlet Hose

Scheme 13

Scheme 13: Charge Air Cooler Outlet Hose Replacement (LAU/A28NER)
Scheme 13: Charge Air Cooler Outlet Hose Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Turn the ignition OFF. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION . Remove the fuel injector sight shield. Refer to UPPER ENGINE COVER REMOVAL . Remove the air cleaner outlet duct. Refer to AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL) . Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT .
1Charge Air Cooler Outlet Hose Fastener (Qty: 2)
2Charge Air Cooler Outlet Hose Fastener (Qty: 3) Refer to FASTENER CAUTION . Tighten 9 Nm (80 lb in)
3Charge Air Cooler Outlet Hose

Scheme 14

Scheme 14: Engine Oil Cooler Connector Replacement
Scheme 14: Engine Oil Cooler Connector Replacement
CalloutComponent Name
Preliminary Procedure Remove the engine cover (V6). Refer to UPPER ENGINE COVER REMOVAL . Remove the engine shield. Refer to ENGINE SHIELD REPLACEMENT . Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) or COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) .
1Engine Oil Cooler Connector (Qty: 2) Procedure Remove the oil cooler coolant inlet hose with the connectors.
2Engine Oil Cooler Connector (Qty: 2) Procedure Remove the oil cooler coolant outlet hose with the connectors. After installation, fill the coolant reservoir to the fill level. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) or COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Inspect cooling system for leaks.

Scheme 15

Scheme 15: Engine Oil Cooler Outlet Hose Replacement
Scheme 15: Engine Oil Cooler Outlet Hose Replacement
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) or COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the secondary air injection pump. Refer to SECONDARY AIR INJECTION PUMP REPLACEMENT (V6) .
1Engine Oil Cooler Outlet Hose Fastener (Qty: 2)
2Engine Oil Cooler Outlet Hose

Scheme 16

Scheme 16: Engine Oil Cooler Pipe Replacement (A28NER/LAU)
Scheme 16: Engine Oil Cooler Pipe Replacement (A28NER/LAU)
CalloutComponent Name
Preliminary Procedure Remove the generator. Refer to ALTERNATOR REPLACEMENT (LAU/A28NER) .
1Engine Oil Cooler Pipe Fastener
2Engine Oil Cooler Pipe Fastener Refer to FASTENER CAUTION . Tighten 38 Nm (28 lb ft)
3Engine Oil Cooler Pipe

Scheme 17

Scheme 17: Engine Oil Cooler Inlet Pipe Replacement
Scheme 17: Engine Oil Cooler Inlet Pipe Replacement
CalloutComponent Name
1Engine Oil Cooler Inlet Pipe Procedure Use a new seal ring.

Scheme 18

Scheme 18: Oil Pump Screen Replacement
Scheme 18: Oil Pump Screen Replacement
CalloutComponent Name
1Oil Pump Screen Fastener (Qty: 2)
2Oil Pump Screen

Scheme 19

Scheme 19: Engine Coolant Fan Motor Replacement (LAU/A28NER)
Scheme 19: Engine Coolant Fan Motor Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Remove the radiator. Refer to RADIATOR REPLACEMENT (LAU/A28NER) . Remove the engine coolant fan shroud. Refer to ENGINE COOLANT FAN SHROUD REPLACEMENT (LAU/A28NER) .
1Engine Coolant Fan Motor Fastener (Qty: 3) Refer to FASTENER CAUTION . Procedure Disconnect the electrical connector of the engine coolant fan motor. Tighten 7 Nm (62 lb in)
2Engine Coolant Fan Motor

Scheme 20

Scheme 20: Engine Coolant Level Indicator Module Replacement
Scheme 20: Engine Coolant Level Indicator Module Replacement
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) or COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the cooling system surge tank. Refer to RADIATOR SURGE TANK REPLACEMENT (LAU/A28NER) .
1Engine Coolant Level Indicator Module

Scheme 21

Scheme 21: Removal Procedure
Scheme 21: Removal Procedure

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25
  1. Remove the fuel injector sight shield. Refer to «UPPER ENGINE COVER REMOVAL»(ref-653637-S35661870322014090100000) .
  2. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  3. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) .
  4. Remove the battery tray. Refer to «BATTERY TRAY»(ref-653644-S29783833042014090100000) .
  5. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  6. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  7. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (6-CYL)»(ref-653660-S06653600572014090100000) .
  8. Remove the charge air cooler outlet hose. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
  9. Remove the engine coolant air bleed pipe. Refer to «UPPER INTAKE MANIFOLD REPLACEMENT»(ref-653637-S16082710212014090100000) .
  10. Remove the turbocharger coolant return pipe and hose (1).
  11. Remove the power brake booster heat shield.
  12. Remove the catalytic converter front heat shield (1).
  13. Remove the transmission heat shield (1).
  14. Remove the generator. Refer to «ALTERNATOR REPLACEMENT (LAU/A28NER)»(ref-653644-S02947685192014090100000) .
  15. Remove the engine oil cooler pipe fastener.
  16. Remove the engine oil cooler pipe from the oil filter adapter.
  17. Remove the secondary air injection pipe. Refer to «SECONDARY AIR INJECTION PIPE REPLACEMENT»(ref-653660-S04576519522014090100000) .
  18. Remove the secondary air injection pump pipe. Refer to «SECONDARY AIR INJECTION PUMP PIPE REPLACEMENT»(ref-653660-S10634382012014090100000) .
  19. Remove the oil level indicator tube. Refer to «OIL LEVEL INDICATOR TUBE REPLACEMENT»(ref-653636-S30255239332014090100000) .
  20. Remove the 2 turbocharger oil feed pipe fittings (2, 6) and gaskets (1, 3).
  21. Remove the turbocharger oil feed pipe fastener (4).
  22. Remove the turbocharger oil feed pipe (5).
  23. Remove the secondary air injection pump. Refer to «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-653660-S40111667292014090100000) .
  24. Disconnect the knock sensor bank 2 electrical connector.
  25. Remove the starter. Refer to «STARTER REPLACEMENT (LAU/A28NER)»(ref-653644-S34804424402014090100000)
  26. Remove the turbocharger coolant feed pipe (1). Refer to «TURBOCHARGER COOLANT FEED PIPE REMOVAL»(ref-653637-S20415531482014090100000) .

Scheme 26

Scheme 26: Installation Procedure
Scheme 26: Installation Procedure

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Install the turbocharger coolant feed pipe (1). Refer to «TURBOCHARGER COOLANT FEED PIPE INSTALLATION»(ref-653637-S16224588022014090100000) .
  2. Install the starter. Refer to «STARTER REPLACEMENT (LAU/A28NER)»(ref-653644-S34804424402014090100000) .
  3. Connect the knock sensor bank 2 electrical connector.
  4. Install the secondary air injection pump. Refer to «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-653660-S40111667292014090100000) .
  5. Install the turbocharger oil feed pipe (5).
  6. Install the NEW turbocharger oil feed pipe fastener gaskets (1, 3).
  7. Install the turbocharger oil feed pipe fastener (4).
  8. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the 2 turbocharger oil feed pipe fittings (2, 6) and tighten the banjo screws to 30 Nm(22 lb ft).
  9. Install the oil level indicator tube. Refer to «OIL LEVEL INDICATOR TUBE REPLACEMENT»(ref-653636-S30255239332014090100000) .
  10. Install the secondary air injection pump pipe. Refer to «SECONDARY AIR INJECTION PUMP PIPE REPLACEMENT»(ref-653660-S10634382012014090100000) .
  11. Install the secondary air injection pipe. Refer to «SECONDARY AIR INJECTION PIPE REPLACEMENT»(ref-653660-S04576519522014090100000) .
  12. Install the engine oil cooler pipe to the oil filter adapter.
  13. Install the engine oil cooler pipe fastener.
  14. Install the generator. Refer to «ALTERNATOR REPLACEMENT (LAU/A28NER)»(ref-653644-S02947685192014090100000) .
  15. Install the transmission heat shield (1).
  16. Install the catalytic converter front heat shield (1).
  17. Install the power brake booster heat shield.
  18. Install the turbocharger coolant return pipe and hose (1).
  19. Install the engine coolant air bleed pipe. Refer to «UPPER INTAKE MANIFOLD REPLACEMENT»(ref-653637-S16082710212014090100000) .
  20. Install the charge air cooler outlet hose. Refer to «CHARGE AIR COOLER OUTLET HOSE REPLACEMENT (LAU/A28NER)»(ref-653648-S09426027062014090100000) .
  21. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY REPLACEMENT (6-CYL)»(ref-653660-S06653600572014090100000) .
  22. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  23. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  24. Install the battery tray. Refer to «BATTERY TRAY»(ref-653644-S29783833042014090100000) .
  25. Connect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  26. Install the fuel injector sight shield. Refer to «UPPER ENGINE COVER REMOVAL»(ref-653637-S35661870322014090100000) .
  27. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) .

Scheme 31

Scheme 31: Turbocharger Coolant Feed Pipe Replacement (LHU/A20NFT)
Scheme 31: Turbocharger Coolant Feed Pipe Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Draining the engine cooling fluid. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the engine sight shield. Refer to ENGINE SIGHT SHIELD REPLACEMENT .
1Turbocharger Coolant Feed Pipe Fastener (Qty: 2) Refer to FASTENER CAUTION . Procedure Use a new gasket. Tighten 35 Nm (26 lb ft)
2Turbocharger Coolant Feed Pipe Retainer (Qty: 2)
3Turbocharger Coolant Feed Pipe Fastener Tighten 10 Nm (89 lb in)
4Turbocharger Coolant Feed Pipe

Scheme 32

Scheme 32: Turbocharger Coolant Return Pipe Replacement (LHU/A20NFT)
Scheme 32: Turbocharger Coolant Return Pipe Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Remove the engine sight shield. Refer to ENGINE SIGHT SHIELD REPLACEMENT . Raise the vehicle by its full height. Refer to LIFTING AND JACKING THE VEHICLE . Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the turbocharger brace. Refer to TURBOCHARGER STAY, REPLACEMENT .
1Turbocharger Coolant Return Pipe Fastener (Qty: 2) Refer to FASTENER CAUTION . Procedure Use a new gasket. Tighten 35 Nm (26 lb ft)
2Turbocharger Coolant Return Pipe

Scheme 33

Scheme 33: Exhaust Gas Recirculation Cooling Pipe Replacement - Lower
Scheme 33: Exhaust Gas Recirculation Cooling Pipe Replacement - Lower
CalloutComponent Name
Preliminary Procedure Remove the exhaust gas recirculation valve cooler.
1Coolant Hose
2Coolant Outlet Pipe Fastener Refer to FASTENER CAUTION . Tighten 9 Nm (80 lb in)
3Exhaust Gas Recirculation Cooling Pipe - Lower

Scheme 34

Scheme 34: Exhaust Gas Recirculation Cooling Pipe Replacement - Upper
Scheme 34: Exhaust Gas Recirculation Cooling Pipe Replacement - Upper
CalloutComponent Name
Preliminary Procedure Drain the coolant. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) or COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the engine cover (V6). Refer to UPPER ENGINE COVER REMOVAL . Detach the charge air cooler outlet pipe for access. Refer to CHARGE AIR COOLER INLET PIPE AND OUTLET PIPE REPLACEMENT (4-CYL) . Remove the engine control module from the battery tray.
1Coolant Hose
2Coolant Outlet Pipe Fastener Refer to FASTENER CAUTION . Tighten 8 Nm (71 lb in)
3Exhaust Gas Recirculation Cooling Pipe - Upper Procedure Inspect cooling system for leaks.

Scheme 35

Scheme 35: Engine Coolant Thermostat Housing Replacement (LAU/A28NER)
Scheme 35: Engine Coolant Thermostat Housing Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (LAU/A28NER) .
1Heater Outlet Pipe Fastener (Qty: 2) Refer to FASTENER CAUTION . Tighten 62 Nm (46 lb ft)
2Heater Outlet Pipe NOTE: Do NOT remove the heater outlet pipe from the vehicle. Install NEW O-ring.
3Radiator Outlet Pipe NOTE: Do NOT remove the radiator outlet pipe from the vehicle. Install NEW O-ring.
4Engine Coolant Thermostat Housing Procedure Remove the engine coolant thermostat housing . Install the engine coolant thermostat housing. Refer to thermostat housing .
NOTE
Do NOT remove the heater outlet pipe from the vehicle. Install NEW O-ring.
NOTE
Do NOT remove the radiator outlet pipe from the vehicle. Install NEW O-ring.

Scheme 36

Scheme 36: Engine Coolant Thermostat Replacement (LHU/A20NFT)
Scheme 36: Engine Coolant Thermostat Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Drain the coolant. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) . Remove the radiator outlet hose. Refer to RADIATOR OUTLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the radiator surge tank engine hose. Refer to RADIATOR SURGE TANK ENGINE HOSE REPLACEMENT .
1Engine Coolant Thermostat Fastener (Qty: 2) Refer to FASTENER CAUTION . Tighten 10 Nm (89 lb in)
2Engine Coolant Thermostat

Scheme 37

Scheme 37: Engine Coolant Air Bleed Pipe Replacement (LAU/A28NER)
Scheme 37: Engine Coolant Air Bleed Pipe Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Remove the fuel injector sight shield. Refer to UPPER ENGINE COVER REMOVAL . Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) .
1Engine Coolant Air Bleed Pipe Fastener (Qty: 3) Refer to FASTENER CAUTION . Tighten 10 Nm (89 lb in)
2Engine Coolant Air Bleed Pipe Fastener (Qty: 2) Procedure Use GE-47622 hose clamp pliers to reposition the engine coolant air bleed pipe clamp. Special Tools GE-47622 Hose Clamp Pliers For equivalent regional tools, refer to SPECIAL TOOLS .
3Engine Coolant Air Bleed Pipe

Scheme 38

Scheme 38: Engine Coolant Air Bleed Hose Replacement (LHU/A20NFT)
Scheme 38: Engine Coolant Air Bleed Hose Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) .
1Engine Coolant Air Bleed Hose Retainer (Qty: 2)
2Engine Coolant Air Bleed Hose

Scheme 39

Scheme 39: Water Outlet Replacement (LAU/A28NER)
Scheme 39: Water Outlet Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) . Remove the charge air cooler outlet air tube. Refer to CHARGE AIR COOLER OUTLET AIR TUBE REPLACEMENT Remove the radiator inlet hose. Refer to RADIATOR INLET HOSE REPLACEMENT (LAU/A28NER) . Remove the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT (6-CYL) .
1Heater Inlet Hose
2Water Outlet Procedure Release retainer with flat bladed screwdriver. NOTE: Install a NEW water outlet O-ring.
NOTE
Install a NEW water outlet O-ring.

Scheme 40

Scheme 40: Removal Procedure
Scheme 40: Removal Procedure

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44
  1. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) .
  2. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT (LAU/A28NER)»(ref-653647-S34692520642014090100000) .
  3. Remove the five exhaust heat shield bank 1 fasteners (1).
  4. Remove the exhaust heat shield bank 1 (2).
  5. Remove the five exhaust turbocharger inlet pipe bank 1 fasteners (3).
  6. Remove the exhaust turbocharger inlet pipe bank 1 (2).
  7. Remove the exhaust turbocharger inlet pipe bank 1 gasket (1).
  8. Remove the lower radiator surge tank hose fastener (2).
  9. Remove the lower radiator surge tank hose (1) from the heater outlet pipe (3).
  10. Raise the vehicle.
  11. Remove the heater outlet hose fastener (2).
  12. Remove the heater outlet hose (3) from the heater outlet pipe (1).
  13. Remove the lower heater outlet pipe fastener (4).
  14. Lower the vehicle.
  15. Remove the upper heater outlet pipe fastener (3).
  16. Remove the heater outlet pipe (2).

Scheme 45

Scheme 45: Installation Procedure
Scheme 45: Installation Procedure

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49
  1. Install a NEW heater outlet pipe O-ring (1).
  2. Install the heater outlet pipe (2).
  3. Install the upper heater outlet pipe fastener (3) and hand tighten the fastener.
  4. Raise the vehicle.
  5. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the lower heater outlet pipe fastener (4) and tighten to 62Nm (46 lb ft).
  6. Install the heater outlet hose (3) to the heater outlet pipe (1).
  7. Install the heater outlet hose fastener (2).
  8. Lower the vehicle.
  9. Install the upper heater outlet pipe fastener and tighten to 62Nm (46 lb ft).
  10. Install the lower radiator surge tank hose (1) to the heater outlet pipe (3).
  11. Install the lower radiator surge tank hose fastener (2).
  12. Install a NEW exhaust turbocharger inlet pipe bank 1 gasket (1).
  13. Install the exhaust turbocharger inlet pipe bank 1 (2).
  14. Install the five NEW exhaust turbocharger inlet pipe bank 1 fasteners (3) and tighten to 30 Nm (22 lb ft).
  15. Install the exhaust heat shield bank 1 (2).
  16. Install the five exhaust heat shield bank 1 fasteners (1) and tighten to 10 Nm (89 lb in).
  17. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT (LAU/A28NER)»(ref-653647-S34692520642014090100000) .
  18. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000) .

Installation Procedure

Note. Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

Scheme 50

Scheme 50: Installation Procedure
Scheme 50: Installation Procedure

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52
Scheme 52
  1. Install the engine coolant fan shroud to the radiator. Refer to «ENGINE COOLANT FAN SHROUD REPLACEMENT (LAU/A28NER)»(ref-653648-S00083646382014090100000) .
  2. With the aid of an assistant, install the radiator.
  3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the radiator fastener (1) and tighten to 25 Nm (18 lb ft).
  4. Install the radiator wiring harness connectors.
  5. Install the radiator outlet hose to the radiator.
  6. Install the relay box (1).
  7. Install the bracket of the power steering fluid cooler. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
  8. Install the engine coolant fan motor wiring harness to the radiator.
  9. Install the charge air cooler. Refer to «CHARGE AIR COOLER RADIATOR REPLACEMENT (LAU/A28NER)»(ref-653648-S37436969952014090100000) .
  10. Vehicles equipped with an automatic transmission, install the upper transmission fluid cooler pipe and the lower transmission fluid cooler pipe to the radiator.
  11. Install the radiator ground cable and tighten to 10 Nm (89 lb in).
  12. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LAU/A28NER)»(ref-653641-S23227615772014090100000) .
  13. Install the radiator air side baffle and the radiator air lower baffle.
  14. Install the secondary air injection pipe. Refer to «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-653660-S40111667292014090100000) .
  15. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  16. Install the radiator inlet hose (1) to the radiator.
  17. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  18. Connect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  19. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER)»(ref-653648-S06131525382014090100000)

Scheme 53

Scheme 53: Removal Procedure
Scheme 53: Removal Procedure

Scheme 54

Scheme 54
Scheme 54
  1. WARNING: With 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. Turn the ignition OFF.
  2. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  3. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  4. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .
  5. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT - UPPER (4-CYL)»(ref-653646-S02731215182014090100000) .
  6. Remove the radiator air side baffle and radiator air lower baffle.
  7. NOTE: Secure the air conditioning condenser with cable ties. Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S37743770902014090100000) .
  8. Remove the radiator inlet hose (1) from the radiator.
  9. Remove the engine coolant fan motor wiring harness from the radiator.
  10. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
  11. NOTE: Secure the power steering fluid cooler with cable ties. Remove the bracket of the power steering fluid cooler. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
  12. NOTE: Secure the transmission fluid cooler pipe with cable ties. Vehicles equipped with an automatic transmission, remove the upper transmission fluid cooler pipe and the lower transmission fluid cooler pipe from the radiator.
  13. Remove the charge air cooler. See «CHARGE AIR COOLER RADIATOR REPLACEMENT (LHU/A20NFT)»(ref-653648-S21062065032014090100000)
  14. With the aid of an assistant, remove the radiator support brackets.
  15. Remove the radiator wiring harness connectors (1).
  16. Remove the radiator (1).
  17. Remove the engine coolant fan shroud from the radiator. Refer to «ENGINE COOLANT FAN SHROUD REPLACEMENT (LHU/A20NFT)»(ref-653648-S31883379702014090100000) .

Note. Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

Scheme 55

Scheme 55: Installation Procedure
Scheme 55: Installation Procedure

Scheme 56

Scheme 56
Scheme 56
  1. Install the engine coolant fan shroud to the radiator. Refer to «ENGINE COOLANT FAN SHROUD REPLACEMENT (LHU/A20NFT)»(ref-653648-S31883379702014090100000) .
  2. With the aid of an assistant, install the radiator (1).
  3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the radiator fastener (1) and tighten the to 25 Nm (15 lb ft).
  4. Install the charge air cooler. Refer to «Charge Air Cooler Radiator Replacement (LHU/A20NFT)»(ref-653648-S21062065032014090100000) .
  5. Install the radiator wiring harness connectors.
  6. Install the radiator outlet hose to the radiator.
  7. Install the radiator inlet hose to the radiator.
  8. Install the engine coolant fan motor wiring harness to the radiator.
  9. Vehicles equipped with an automatic transmission, install the upper transmission fluid cooler pipe and the lower transmission fluid cooler pipe to the radiator.
  10. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT)»(ref-653641-S37743770902014090100000) .
  11. Install the radiator air side baffle and the radiator air lower baffle.
  12. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT - UPPER (4-CYL)»(ref-653646-S02731215182014090100000) .
  13. Connect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  14. Fill the cooling system. Refer to «COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT)»(ref-653648-S39426541432014090100000) .

Scheme 57

Scheme 57: Removal Procedure
Scheme 57: Removal Procedure
  1. Turn the ignition OFF.
  2. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  3. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  4. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  5. Remove the radiator air side baffle and radiator air lower baffle.
  6. NOTE: Secure the air conditioning condenser with cable ties. Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LAU/A28NER)»(ref-653641-S23227615772014090100000) and «AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT (LAU/A28NER)»(ref-653641-S42139567902014090100000) .
  7. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
  8. NOTE: Secure the power steering fluid cooler with cable ties. Remove the bracket of the power steering fluid cooler. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
  9. Remove the charge air cooler outlet hose from the charge air cooler. Refer to «CHARGE AIR COOLER OUTLET HOSE REPLACEMENT (LAU/A28NER)»(ref-653648-S09426027062014090100000) .
  10. Remove the «charge air cooler inlet»(ref-653648-S28332889932014090100000) hose from the charge air cooler.
  11. With the aid of an assistant remove the charge air cooler radiator (2) from the radiator (1).
  12. Remove the charge air cooler.

Note. Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

Scheme 58

Scheme 58: Installation Procedure
Scheme 58: Installation Procedure
  1. Install the charge air cooler.
  2. With the aid of an assistant install the charge air cooler radiator (2) to the radiator (1).
  3. Install the air conditioning condenser to the radiator assembly. Refer to «AIR CONDITIONING CONDENSER REPLACEMENT (LAU/A28NER)»(ref-653641-S27935582692014090100000) .
  4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the radiator ground cable and tighten to 10 Nm (89 lb in).
  5. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose. Refer to «AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LAU/A28NER)»(ref-653641-S23227615772014090100000) or «AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT (LAU/A28NER)»(ref-653641-S42139567902014090100000) .
  6. Install the power steering fluid cooler. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
  7. Install the radiator air side baffle and the radiator air lower baffle.
  8. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT (6-CYL)»(ref-653660-S31000862622014090100000) .
  9. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  10. Connect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .

Scheme 59

Scheme 59: Removal Procedure
Scheme 59: Removal Procedure
  1. Turn the ignition OFF.
  2. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .
  3. Remove the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  4. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT - UPPER (4-CYL)»(ref-653646-S02731215182014090100000) .
  5. Remove the radiator air side baffle and radiator air lower baffle.
  6. NOTE: Secure the air conditioning condenser with cable ties. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-653635-S17278308762014090100000) .
  7. NOTE: Secure the power steering fluid cooler with cable ties. Remove the bracket of the power steering fluid cooler. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
  8. Remove the charge air cooler outlet hose from the charge air cooler. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
  9. Remove the charge air cooler inlet hose from the charge air cooler. See «CHARGE AIR COOLER INLET AIR TUBE REPLACEMENT»(ref-653636-S17400529052014090100000)
  10. With the aid of an assistant remove the charge air cooler radiator (2) from the radiator (1).
  11. Remove the charge air cooler.

Note. Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

Scheme 60

Scheme 60: Installation Procedure
Scheme 60: Installation Procedure
  1. Install the charge air cooler.
  2. With the aid of an assistant install the charge air cooler radiator (2) to the radiator (1).
  3. Install the air conditioning condenser to the radiator assembly. Refer to «AIR CONDITIONING CONDENSER REPLACEMENT (LHU/A20NFT)»(ref-653641-S20186701012014090100000) .
  4. Install the charge air cooler inlet hose to the charge air cooler. Refer to «CHARGE AIR COOLER INLET AIR TUBE REPLACEMENT»(ref-653636-S17400529052014090100000) .
  5. Install the charge air cooler outlet hose to the charge air cooler. Refer to «CHARGE AIR COOLER OUTLET AIR HOSE REPLACEMENT»(ref-653636-S39117490072014090100000) .
  6. Install the power steering fluid cooler. Refer to «POWER STEERING FLUID COOLER REPLACEMENT»(ref-653656-S08956749912014090100000) .
  7. Install the radiator air side baffle and the radiator air lower baffle.
  8. Install the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT - UPPER (4-CYL)»(ref-653646-S02731215182014090100000) .
  9. Install the front bumper fascia. Refer to «FRONT BUMPER FASCIA REPLACEMENT»(ref-653649-S28914650632014090100000) .
  10. Connect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-653644-S42080336692014090100000) .

Scheme 61

Scheme 61: Radiator Support Replacement
Scheme 61: Radiator Support Replacement
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia. Refer to FRONT BUMPER FASCIA REPLACEMENT Support the radiator.
1Radiator Support Fastener (Qty: 4) Refer to FASTENER CAUTION . Procedure Support the radiator. Tighten 25 Nm (18 lb ft)
2Radiator Support (Qty: 2)

Scheme 62

Scheme 62: Radiator Air Side Baffle and Deflector Replacement
Scheme 62: Radiator Air Side Baffle and Deflector Replacement
CalloutComponent Name
Preliminary Procedure Remove the left side front bumper fascia support. Refer to FRONT BUMPER FASCIA SUPPORT REPLACEMENT (LEFT SIDE) .
1Radiator Air Side Baffle and Deflector NOTE: Release the air side baffle from the support by releasing the two hooks.
NOTE
Release the air side baffle from the support by releasing the two hooks.

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