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Engine Cooling System: Removal & Installation Saturn Aura I

Cooling System (Mechanical) 15 illustrations ~5824 words

Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5)

CalloutComponent Name
Preliminary Procedure CAUTION: 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. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Radiator Surge Tank Inlet Hose Tip: Using J 38185 Hose Clamp Pliers reposition the surge tank inlet hose clamps. See Special Tools . Remove the surge tank inlet hose from the surge tank and intake.
CAUTION
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 4

Scheme 4: Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7)
Scheme 4: Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7)
CalloutComponent Name
CAUTION: 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: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Surge Tank Outlet Hose Procedure: Reposition the 2 surge tank hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 5

Scheme 5: Radiator Surge Tank Outlet Hose/Pipe Replacement (LAT)
Scheme 5: Radiator Surge Tank Outlet Hose/Pipe Replacement (LAT)
CalloutComponent Name
CAUTION: 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: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Surge Tank Outlet Hose Procedure: Reposition the 2 surge tank hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 Surge Tank Outlet Hose/Pipe Replacement (LE5)
Scheme 6: Radiator Surge Tank Outlet Hose/Pipe Replacement (LE5)
CalloutComponent Name
Preliminary Procedure: CAUTION: 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. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Radiator Surge Tank Outlet Hose Clamp (Qty: 2)
2Radiator Surge Tank Outlet Hose Procedure: Using J 38185 to reposition of the radiator surge tank outlet hose clamps. See Special Tools . Remove the radiator surge tank outlet hose from the surge tank and radiator outlet hose.
CAUTION
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 7

Scheme 7: Radiator Inlet Hose Replacement (LZ4)
Scheme 7: Radiator Inlet Hose Replacement (LZ4)
CalloutComponent Name
CAUTION: 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: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Radiator Inlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 8

Scheme 8: Radiator Inlet Hose Replacement (LAT)
Scheme 8: Radiator Inlet Hose Replacement (LAT)
CalloutComponent Name
CAUTION: 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 Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Duct Replacement (1st Design) or Air Cleaner Outlet Duct Replacement (2nd Design) .
1Radiator Inlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 9

Scheme 9: Radiator Inlet Hose Replacement (LY7)
Scheme 9: Radiator Inlet Hose Replacement (LY7)
CalloutComponent Name
CAUTION: 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: Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Radiator Inlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 10

Scheme 10: Radiator Inlet Hose Replacement (LE5)
Scheme 10: Radiator Inlet Hose Replacement (LE5)
CalloutComponent Name
Preliminary Procedure: CAUTION: 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. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Radiator Inlet Hose Tip: Using J 38185 reposition the radiator inlet hose clamps. See Special Tools . Remove the radiator inlet hose from the radiator and engine.
CAUTION
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 11

Scheme 11: Radiator Outlet Hose Replacement (LY7)
Scheme 11: Radiator Outlet Hose Replacement (LY7)
CalloutComponent Name
CAUTION: 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 Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1Radiator Outlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 12

Scheme 12: Radiator Outlet Hose Replacement (LAT)
Scheme 12: Radiator Outlet Hose Replacement (LAT)
CalloutComponent Name
CAUTION: 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 Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the electronic control module (ECM). Refer to Engine Control Module Replacement .
1Radiator Outlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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 13

Scheme 13: Radiator Outlet Hose Replacement (LZ4)
Scheme 13: Radiator Outlet Hose Replacement (LZ4)
CalloutComponent Name
CAUTION: 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 (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) .
1Radiator Outlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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.

Removal Procedure

  1. Drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  3. Remove the radiator outlet hose from the radiator.
  4. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  5. Remove the radiator outlet hose from the engine.
  6. Remove the radiator outlet hose clamps from the radiator outlet hose.

Installation Procedure

  1. Install the radiator outlet hose clamps to the radiator outlet hose.
  2. Install the radiator outlet hose to the engine.
  3. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  4. Install the radiator outlet hose to the radiator.
  5. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  6. Fill the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .

Scheme 14

Scheme 14: Radiator Outlet Pipe Replacement (LAT)
Scheme 14: Radiator Outlet Pipe Replacement (LAT)
CalloutComponent Name
CAUTION: 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 Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the electronic control module (ECM). Refer to Engine Control Module Replacement .
1Radiator Outlet Hose Procedure: Reposition the 2 hose clamps per hose, using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
2Generator Control Module Coolant Pump Hose
3Generator Control Module Coolant Outlet Hose
4Radiator Outlet Pipe Nut NOTE: Refer to Fastener Notice . Tighten: 20 N.m (15 lb ft)
5Radiator Outlet Pipe
CAUTION
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.
NOTE
Refer to Fastener Notice .

Scheme 15

Scheme 15: Radiator Outlet Hose Replacement - Radiator Outlet Pipe to Engine Coolant Thermostat Housing Pipe (L
Scheme 15: Radiator Outlet Hose Replacement - Radiator Outlet Pipe to Engine Coolant Thermostat Housing Pipe (L
CalloutComponent Name
CAUTION: 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 Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) or Cooling System Draining and Filling (GE 47716 Fill) . Remove the electronic control module (ECM). Refer to Engine Control Module Replacement .
1Radiator Outlet Hose Procedure: Reposition the 2 radiator hose clamps using the J 38185 . See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools .
CAUTION
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.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the air cleaner air duct. Refer to the following: «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) for the 2.4L engine «Air Cleaner Inlet Duct Replacement»(ref-301532-S38085333602008101700000) for the 3.5L engine «Air Cleaner Inlet Duct Replacement»(ref-301503-S25860133782008101700000) for the 3.6L engine
  3. Remove the upper radiator air deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-301507-S30511318262008101700000) .
  4. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-301483-S28065833722008101700000) for the 4T45-E transaxle.
  5. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
  6. Remove the upper radiator support bracket bolts.
  7. Remove the upper radiator support brackets.
  8. Pry upward on the fan shroud tabs at the radiator clips to release the fan shroud from the radiator.
  9. Remove the lower radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
  10. Lower the vehicle.
  11. Remove the radiator inlet hose from the radiator. Refer to «Radiator Inlet Hose Replacement (LZ4)»(ref-301507-S02877261192008101700000) or «Radiator Inlet Hose Replacement (LAT)»(ref-301507-S39262997152008101700000) or «Radiator Inlet Hose Replacement (LY7)»(ref-301507-S08340301762008101700000) or «Radiator Inlet Hose Replacement (LE5)»(ref-301507-S10295693522008101700000) .
  12. Remove the radiator outlet hose from the radiator. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-301507-S27511827622008101700000) or «Radiator Outlet Hose Replacement (LAT)»(ref-301507-S23621310922008101700000) or «Radiator Outlet Hose Replacement (LZ4)»(ref-301507-S42287877592008101700000) or «Radiator Outlet Hose Replacement (LE5)»(ref-301507-S14537066042008101700000) .
  13. Disconnect the cooling fan wire harness connectors.
  14. Remove the A/C compressor and condenser hose assembly. Refer to «Air Conditioning Compressor and Condenser Hose Replacement (LY7)»(ref-301492-S29172331152008101700000) or «Air Conditioning Compressor and Condenser Hose Replacement (LE5)»(ref-301492-S01397939332008101700000) or «Air Conditioning Compressor and Condenser Hose Replacement (LZ4)»(ref-301492-S16922232402008101700000) or «Air Conditioning Compressor and Condenser Hose Replacement (LAT)»(ref-301492-S25145502622008101700000) .
  15. Raise the vehicle.
  16. Remove the lower radiator support bracket bolts.
  17. Remove the lower radiator support brackets.
  18. Remove the transmission oil cooler pipe clip from the fan shroud.
  19. Remove the fan shroud assembly.
  1. Install the fan shroud assembly.
  2. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-301483-S28065833722008101700000) for the 4T45-E transaxle.
  3. Install the transmission oil cooler pipe clip to the fan shroud.
  4. Install the lower radiator support brackets.
  5. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  6. Install the cooling fan wire harness connectors.
  7. Install the radiator outlet hose to the radiator. Refer to «Radiator Outlet Hose Replacement (LY7)»(ref-301507-S27511827622008101700000) or «Radiator Outlet Hose Replacement (LAT)»(ref-301507-S23621310922008101700000) or «Radiator Outlet Hose Replacement (LZ4)»(ref-301507-S42287877592008101700000) or «Radiator Outlet Hose Replacement (LE5)»(ref-301507-S14537066042008101700000) .
  8. Install the lower radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
  9. Lower the vehicle.
  10. Snap fan shroud tabs into the radiator clips.
  11. Remove the rope attached to the condenser and upper tie bar.
  12. Install the upper radiator support brackets.
  13. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  14. Install the radiator inlet hose to the radiator. Refer to «Radiator Inlet Hose Replacement (LZ4)»(ref-301507-S02877261192008101700000) or «Radiator Inlet Hose Replacement (LAT)»(ref-301507-S39262997152008101700000) or «Radiator Inlet Hose Replacement (LY7)»(ref-301507-S08340301762008101700000) or «Radiator Inlet Hose Replacement (LE5)»(ref-301507-S10295693522008101700000) .
  15. Install the A/C compressor and condenser hose assembly. Refer to «Air Conditioning Compressor and Condenser Hose Replacement (LY7)»(ref-301492-S29172331152008101700000) or «Air Conditioning Compressor and Condenser Hose Replacement (LE5)»(ref-301492-S01397939332008101700000) or «Air Conditioning Compressor and Condenser Hose Replacement (LZ4)»(ref-301492-S16922232402008101700000) or «Air Conditioning Compressor and Condenser Hose Replacement (LAT)»(ref-301492-S25145502622008101700000) .
  16. Install the upper radiator air deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(ref-301507-S30511318262008101700000) .
  17. Install the air cleaner air duct. Refer to the following: «Air Cleaner Outlet Duct Replacement (1st Design)»(ref-301531-S42378676562008101700000) or «Air Cleaner Outlet Duct Replacement (2nd Design)»(ref-301531-S19345139462008101700000) for the 2.4L engine «Air Cleaner Inlet Duct Replacement»(ref-301532-S38085333602008101700000) for the 3.5L engine «Air Cleaner Inlet Duct Replacement»(ref-301503-S25860133782008101700000) for the 3.6L engine
  18. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  19. Inspect the transmission fluid level. Refer to «Transmission Fluid Check»(ref-301483-S08540686992008101700000) for the 4T45-E transaxle or «Transmission Fluid Check»(ref-301510-S22343488912008101700000) for the 6T70/6T75 transaxle.
  1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the radiator outlet hose from the thermostat housing.
  3. Remove the heater inlet and outlet hoses.
  4. Remove the surge tank outlet hose.
  5. Remove the thermostat housing bolts (1).
  6. Remove the housing.
  1. Install the thermostat housing bolts. Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).
  2. Install the surge tank outlet hose.
  3. Install the heater inlet and outlet hoses.
  4. Install the radiator outlet hose to the thermostat housing.
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
  3. Reposition the radiator outlet hose clamp at the thermostat housing.
  4. Remove the radiator outlet hose from the thermostat housing.
  5. Remove the thermostat housing bolt/stud.
  6. Remove the thermostat housing and gasket.
  7. Clean the gasket surfaces.
  1. Position a NEW gasket and the thermostat housing to the engine block.
  2. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
  3. Install the radiator outlet hose to the thermostat housing.
  4. Position the radiator outlet hose clamp at the thermostat housing.
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  7. Inspect the system for leaks.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  3. Lower the vehicle.
  4. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) or «Battery Tray Replacement (LZ4/LY7)»(ref-301498-S22879190742008101700000) .
  5. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
  6. Remove the heated oxygen sensor (HO2S) electrical connector rosebud clip from the thermostat housing.
  7. Reposition the radiator outlet hose clamp at the thermostat cover.
  8. Remove the radiator outlet hose from the thermostat cover.
  9. Remove the exhaust heat shield bolts (1).
  10. Remove the exhaust heat shield.
  11. Remove the auxiliary heater water pump hose clip (1) from the heater outlet hose.
  12. Reposition the auxiliary heater water pump hose clamp at the thermostat housing.
  13. Remove the auxiliary heater water pump hose (2) from the thermostat housing.
  14. Reposition the heater inlet hose clamp at the thermostat housing.
  15. Remove the heater inlet hose (3) from the thermostat housing.
  16. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  17. Remove the ECT sensor, if necessary.
  18. Remove the thermostat housing bolts.
  19. Remove the thermostat from the vehicle.
  20. Remove the water transfer pipe from the thermostat housing, if necessary.
  21. Remove and discard the water transfer pipe O-ring seals, if necessary.
  22. Remove the thermostat cover bolts and cover, if necessary.
  23. Remove the thermostat, if necessary.
  24. Remove and discard the thermostat cover O-ring seal, if necessary.
  25. Remove all debris and thread sealant from the engine coolant temperature (ECT) sensor and bolt holes if the housing is being re-used.
  1. Install a NEW thermostat cover O-ring seal into the recess groove.
  2. Install the thermostat, if necessary.
  3. Install the thermostat cover bolts, if necessary. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install a NEW thermostat housing to engine gasket onto the thermostat housing.
  5. Load the thermostat housing assembly into position.
  6. Install NEW O-ring seals onto the water feed pipe.
  7. Install the water feed pipe into the thermostat housing aligning locator tab.
  8. Align the water pipe to water pump.
  9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  10. Position the thermostat housing against the engine.
  11. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  12. If reinstalling the old sensor, coat the threads with sealant. Refer to «Sealers, Adhesives, and Lubricants»(ref-301512-S04824426002008101700000) .
  13. Install the ECT sensor, if necessary. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  14. Lower the vehicle.
  15. Install the heater inlet hose (3) to the thermostat housing.
  16. Position the heater inlet hose clamp at the thermostat housing.
  17. Install the auxiliary heater water pump hose (2) to the thermostat housing.
  18. Position the auxiliary heater water pump hose clamp at the thermostat housing.
  19. Install the auxiliary heater water pump hose clip (1) to the heater outlet hose.
  20. Install the exhaust heat shield.
  21. Install the exhaust heat shield bolts. Tighten: Tighten the studs to 22 N.m (16 lb ft).
  22. Install the radiator outlet hose to the thermostat cover.
  23. Position the radiator outlet hose clamp at the thermostat cover.
  24. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
  25. Install the HO2S electrical connector rosebud clip to the thermostat housing.
  26. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) or «Battery Tray Replacement (LZ4/LY7)»(ref-301498-S22879190742008101700000) .
  27. Verify the drain valves at the radiator and water pump are closed.
  28. Lower the vehicle.
  29. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the radiator outlet hose from the thermostat housing.
  3. Remove the heater inlet and outlet hoses.
  4. Remove the surge tank outlet hose.
  5. Remove the thermostat housing bolts (1).
  6. Remove the housing.
  7. Remove the thermostat (2) and discard the thermostat gasket.
  1. Install the thermostat (2) with a NEW thermostat gasket.
  2. Install the thermostat housing bolts (1). Tighten: Tighten the thermostat housing bolts to 10 N.m (89 lb in).
  3. Install the surge tank outlet hose.
  4. Install the heater inlet and outlet hoses.
  5. Install the radiator outlet hose to the thermostat housing.
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Reposition the radiator outlet hose clamp at the thermostat cover.
  3. Remove the radiator outlet hose from the thermostat cover.
  4. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) or «Battery Tray Replacement (LZ4/LY7)»(ref-301498-S22879190742008101700000) .
  5. Remove the thermostat cover bolts and cover.
  6. Remove the thermostat.
  7. Remove and discard the thermostat cover O-ring seal.
  1. Install a NEW thermostat cover O-ring seal.
  2. Install the thermostat.
  3. Install the thermostat cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(ref-301498-S25876329792008101700000) or «Battery Tray Replacement (LZ4/LY7)»(ref-301498-S22879190742008101700000) .
  5. Install the radiator outlet hose to the thermostat cover.
  6. Position the radiator outlet hose clamp at the thermostat cover.
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
  3. Reposition the radiator outlet hose clamp at the thermostat housing.
  4. Remove the radiator outlet hose from the thermostat housing.
  5. Remove the thermostat housing bolt/stud.
  6. Remove the thermostat housing and gasket.
  7. Remove the thermostat.
  8. Clean the gasket surfaces.
  1. Install a NEW thermostat.
  2. Position a NEW gasket and the thermostat housing to the engine block.
  3. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
  4. Install the radiator outlet hose to the thermostat housing.
  5. Position the radiator outlet hose clamp at the thermostat housing.
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-301532-S34522201942008101700000) .
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  8. Inspect the system for leaks.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
  2. Remove the generator. Refer to «Generator Replacement (LZ4)»(ref-301498-S13888012732008101700000) or «Generator Replacement (LY7)»(ref-301498-S23851025832008101700000) .
  3. Remove the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(ref-301513-S16314418562008101700000) .
  4. Remove the power steering pump. Refer to «Power Steering Pump Replacement (LZ4)»(ref-301509-S08543598372008101700000) or «Power Steering Pump Replacement (LY7)»(ref-301509-S03493390092008101700000) .
  5. Reposition the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
  6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way.
  7. Remove the radiator surge tank pipe bolts (2).
  8. Remove the radiator surge tank pipe from the crossover pipe.
  9. Reposition the radiator inlet hose clamp at the crossover pipe.
  10. Remove the radiator inlet hose from the crossover pipe.
  11. Reposition the thermal bypass hose clamp at the crossover pipe.
  12. Remove the thermal bypass hose from the crossover pipe.
  13. Remove the coolant crossover pipe bolts (1-4).
  14. Remove the coolant crossover pipe.
  1. Position the coolant crossover pipe to the cylinder heads.
  2. Install the coolant crossover pipe bolts (1-4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  3. Install the thermal bypass hose to the crossover pipe.
  4. Position the thermal bypass hose clamp at the crossover pipe.
  5. Install the radiator inlet hose to the crossover pipe.
  6. Position the radiator inlet hose clamp at the crossover pipe.
  7. Install the radiator surge tank pipe to the crossover pipe.
  8. Install the radiator surge tank pipe bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  9. Install the radiator surge tank inlet hose to the inlet pipe.
  10. Position the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
  11. Install the power steering pump. Refer to «Power Steering Pump Replacement (LZ4)»(ref-301509-S08543598372008101700000) or «Power Steering Pump Replacement (LY7)»(ref-301509-S03493390092008101700000) .
  12. Install the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(ref-301513-S16314418562008101700000) .
  13. Install the generator. Refer to «Generator Replacement (LZ4)»(ref-301498-S13888012732008101700000) or «Generator Replacement (LY7)»(ref-301498-S23851025832008101700000) .
  14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
  2. Remove the surge tank inlet hose. Refer to «Radiator Surge Tank Inlet Hose/Pipe Replacement (LAT)»(ref-301507-S11319811772008101700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LZ4)»(ref-301507-S41495694682008101700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)»(ref-301507-S06853887392008101700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5)»(ref-301507-S01198201082008101700000) .
  3. Remove the fuel feed pipe line nut (2).
  4. Remove the fuel feed line clip from the stud and reposition the fuel feed line.
  5. Remove the coolant air bleed hose/pipe bolt (3) from the upper intake manifold.
  6. Reposition the coolant air bleed hose clamp (2) at the water outlet.
  7. Remove the coolant air bleed hose from the water outlet.
  8. Remove the coolant air bleed hose/pipe from the engine.
  1. Install the coolant air bleed hose/pipe to the engine.
  2. Install the coolant air bleed hose to the water outlet.
  3. Position the coolant air bleed hose clamp (2) at the water outlet.
  4. Install the coolant air bleed hose/pipe bolt (3) to the upper intake manifold. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. Position the fuel feed line and install the fuel feed line clip to the stud.
  6. Install the fuel feed pipe line nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
  7. Install the surge tank inlet hose. Refer to «Radiator Surge Tank Inlet Hose/Pipe Replacement (LAT)»(ref-301507-S11319811772008101700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LZ4)»(ref-301507-S41495694682008101700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)»(ref-301507-S06853887392008101700000) or «Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5)»(ref-301507-S01198201082008101700000) .
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-301513-S28448662712008101700000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301505-S42749017972008101700000) .
  3. Use the EN 46104 in order to retain the water pump pulley.
  4. Remove the water pump pulley bolts.
  5. Remove the water pump pulley.
  6. Remove the water pump bolts.
  7. Remove the water pump.
  8. Remove and DISCARD the water pump seal.
  9. Carefully clean the water pump sealing surfaces.
  1. Install a NEW water pump seal.
  2. Install the water pump.
  3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
  4. Install the water pump pulley and the water pump pulley bolts.
  5. Use the EN 46104 in order to retain the water pump pulley.
  6. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 10 N.m (89 lb in).
  7. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301505-S42749017972008101700000) .
  8. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  1. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LY7)»(ref-301507-S24779249102008101700000) or «Engine Coolant Thermostat Housing Replacement (LZ4)»(ref-301507-S09942977082008101700000) or «Engine Coolant Thermostat Housing Replacement (LAT)»(ref-301507-S23818913702008101700000) .
  2. Remove the engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-301500-S42272808122008101700000) .
  3. Remove the water pump access plate from the front cover.
  4. Drain the coolant from the water pump using the plug at the bottom of the pump.
  5. Install the J 43651 (1) into position. See «Special Tools»(ref-301507-S03788199182008101700000) .
  6. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
  7. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
  8. Remove the 3 inner water pump sprocket to water pump blots.
  9. Remove the 2 water pump bolts.
  10. Remove the rear 2 water pump bolts.
  11. Remove the water pump.
  12. Remove and discard the water pump O-ring seal.
  1. Install a NEW water pump O-ring seal.
  2. Using the guide pin, align the pin with the water pump holding tool.
  3. Position the water pump against the engine block and hand tighten the water pump bolts.
  4. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten: Tighten the water pump bolts to 25 N.m (18 lb ft).
  5. Tighten the water pump sprocket bolts last. Tighten: Tighten the water pump sprocket bolts to 10 N.m (89 lb in).
  6. Remove the J 43651 (1). See «Special Tools»(ref-301507-S03788199182008101700000) .
  7. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Install the engine splash shield. Refer to «Engine Splash Shield Replacement»(ref-301500-S42272808122008101700000) .
  9. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LY7)»(ref-301507-S24779249102008101700000) or «Engine Coolant Thermostat Housing Replacement (LZ4)»(ref-301507-S09942977082008101700000) or «Engine Coolant Thermostat Housing Replacement (LAT)»(ref-301507-S23818913702008101700000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Loosen the water pump pulley bolts.
  3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .
  4. Remove the water pump pulley bolts and pulley.
  5. Remove the water pump bolts.
  6. Remove the water pump and gasket.
  7. Clean the water pump mating surfaces.
  1. Position a NEW water pump gasket and the water pump to the engine front cover.
  2. Install the water pump bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the water pump pulley and bolts.
  4. Install the drive belt. Refer to «Drive Belt Replacement»(ref-301513-S36274356542008101700000) .
  5. Tighten the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  6. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  7. Inspect for leaks.
  1. Drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
  3. Remove the upper radiator support brackets. Refer to «Radiator Support Bracket Replacement»(ref-301507-S00793243542008101700000) .
  4. Reposition the radiator inlet hose clamp at the radiator using the pliers J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  5. Remove the radiator inlet hose from the radiator.
  6. Remove the front air dam. Refer to «Front Air Dam Replacement»(ref-301478-S06070260642008101700000) . .
  7. Remove the right engine splash shield retainers.
  8. Remove the right engine splash shield.
  9. Remove the left engine splash shield retainers.
  10. Remove the left engine splash shield.
  11. Reposition the radiator outlet hose clamp at the radiator using the pliers J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  12. Remove the radiator outlet hose from the radiator.
  13. Remove the transmission oil cooler pipes from the radiator.
  14. Remove the lower radiator support bracket bolts.
  15. Remove the lower radiator support brackets.
  16. Remove the radiator lower mounts.
  17. Remove and discard the condenser mounting bolts from the radiator.
  18. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
  19. Remove and discard the condenser mounting nuts from the radiator.
  20. Remove the radiator air side seals.
  21. Remove the radiator and cooling fan shroud assembly from the vehicle.
  22. Pry upward on the fan shroud tabs at the radiator clips.
  23. Remove the cooling fan and shroud assembly from the radiator.
  1. Install the cooling fan and shroud assembly to the radiator.
  2. Snap the fan shroud tabs into the radiator clips.
  3. Install the radiator and cooling fan shroud assembly to the vehicle.
  4. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
  5. Install the condenser mounting nuts to the radiator.
  6. Insert the condenser mounting tabs into the radiator clips.
  7. Install the condenser to the radiator bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
  8. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  9. The radiator air side seals must be in the proper position for proper air flow.
  10. Install the radiator lower mounts.
  11. Install the lower radiator support brackets.
  12. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  13. Install the transmission oil cooler pipes to the radiator.
  14. Install the radiator outlet hose to the radiator.
  15. Reposition the radiator outlet hose clamp at the radiator using the pliers J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  16. Install the left engine splash shield.
  17. Install the left engine splash shield retainers.
  18. Install the right engine splash shield.
  19. Install the right engine splash shield retainers.
  20. Install the front air dam. Refer to «Front Air Dam Replacement»(ref-301478-S06070260642008101700000) .
  21. Lower the vehicle.
  22. Install the radiator inlet hose to the radiator.
  23. Reposition the radiator inlet hose clamp at the radiator using the pliers J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  24. Remove the rope attached to the condenser and upper tie bar.
  25. Install the upper radiator support brackets. Refer to «Radiator Support Bracket Replacement»(ref-301507-S00793243542008101700000) .
  26. Fill the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  27. Inspect the transmission fluid level. Refer to «Transmission Fluid Check»(ref-301510-S22343488912008101700000) .
  1. Drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
  3. Remove the upper radiator support brackets. Refer to «Radiator Support Bracket Replacement»(ref-301507-S00793243542008101700000) .
  4. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  5. Remove the radiator inlet hose from the radiator.
  6. Remove the front air dam. Refer to «Front Air Dam Replacement»(ref-301478-S06070260642008101700000) .
  7. Remove the right engine splash shield retainers.
  8. Remove the right engine splash shield.
  9. Remove the left engine splash shield retainers.
  10. Remove the left engine splash shield.
  11. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  12. Remove the radiator outlet hose from the radiator.
  13. Remove the transmission oil cooler pipes from the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-301483-S28065833722008101700000) .
  14. Remove the lower radiator support bracket bolts.
  15. Remove the lower radiator support brackets.
  16. Remove the radiator lower mounts.
  17. Remove and discard the condenser mounting bolts from the radiator.
  18. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
  19. Remove and discard the condenser mounting nuts from the radiator.
  20. Remove the radiator air side seals.
  21. Remove the radiator and cooling fan shroud assembly from the vehicle.
  22. Pry upward on the fan shroud tabs at the radiator clips.
  23. Remove the cooling fan and shroud assembly from the radiator.
  1. Install the cooling fan and shroud assembly to the radiator.
  2. Snap the fan shroud tabs into the radiator clips.
  3. Install the radiator and cooling fan shroud assembly to the vehicle.
  4. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
  5. Install the condenser mounting nuts to the radiator.
  6. Insert the condenser mounting tabs into the radiator clips.
  7. Install the condenser to the radiator bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
  8. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  9. The radiator air side seals must be in the proper position for proper air flow.
  10. Install the radiator lower mounts.
  11. Install the lower radiator support brackets.
  12. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  13. Install the transmission oil cooler pipes to the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-301483-S28065833722008101700000) .
  14. Install the radiator outlet hose to the radiator.
  15. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  16. Install the left engine splash shield.
  17. Install the left engine splash shield retainers.
  18. Install the right engine splash shield.
  19. Install the right engine splash shield retainers.
  20. Install the front air dam. Refer to «Front Air Dam Replacement»(ref-301478-S06070260642008101700000) .
  21. Lower the vehicle.
  22. Install the radiator inlet hose to the radiator.
  23. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-301507-S03788199182008101700000) .
  24. Remove the rope attached to the condenser and upper tie bar.
  25. Install the upper radiator support brackets. Refer to «Radiator Support Bracket Replacement»(ref-301507-S00793243542008101700000) .
  26. Fill the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  27. Inspect the transmission fluid level. Refer to «Transmission Fluid Check»(ref-301483-S08540686992008101700000) .
  1. Remove the cooling fan and shroud assembly. Refer to «Cooling Fan and Shroud Replacement»(ref-301507-S40014758652008101700000) .
  2. Remove and discard the condenser mounting bolts.
  3. Push upward on the condenser and downward on the radiator to unsnap the condenser mounting tabs from the radiator clips.
  4. Remove and discard the condenser mounting nuts from the radiator.
  5. Remove the radiator from the vehicle.
  1. Install the radiator to the vehicle.
  2. Push upward on the radiator and downward on the condenser to snap the condenser mounting tabs into the radiator clips.
  3. Install new condenser mounting nut to the radiator. Tighten: Tighten the nuts to 6 N.m (53 lb in).
  4. Install new condenser mounting bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
  5. Install the cooling fan and shroud assembly. Refer to «Cooling Fan and Shroud Replacement»(ref-301507-S40014758652008101700000) .

Scheme 16

Scheme 16: Radiator Support Bracket Replacement
Scheme 16: Radiator Support Bracket Replacement
CalloutComponent Name
Preliminary Procedure: Remove the front fascia upper support grille. Refer to Front Bumper Upper Fascia Grille Replacement .
1Radiator Upper Bracket Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 10 N.m (89 lb in)
2Radiator Upper Bracket (Qty: 2)
NOTE
Refer to Fastener Notice .

Scheme 17

Scheme 17: Radiator Support Replacement
Scheme 17: Radiator Support Replacement
CalloutComponent Name
Preliminary Procedure: Remove the lower radiator air baffle and deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement .
1Radiator Support Bracket Bolt (Qty: 2) NOTE: Refer to Fastener Notice . Tighten: 60 N.m (44 lb ft)
2Radiator Support Bracket - Lower Tip: Left shown and right is similar. Support the radiator and condenser assembly with a suitable jack.
NOTE
Refer to Fastener Notice .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  2. Remove the lower radiator air deflector retainers.
  3. Remove the lower radiator air deflector.
  1. Install the lower radiator air deflector.
  2. Install the lower radiator air deflector retainers.
  3. Lower the vehicle.
  1. Remove the upper front fascia. Refer to «Front Bumper Fascia Replacement»(ref-301478-S27132323142008101700000) .
  2. Remove the lower radiator air baffle. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
  3. Remove the side radiator air deflector retainer.
  4. Remove the side radiator air deflector.
  1. Install the side radiator air deflector.
  2. Install the side radiator air deflector retainer.
  3. Install the lower radiator air baffle. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(ref-301507-S41457736352008101700000) .
  4. Install the upper front fascia. Refer to «Front Bumper Fascia Replacement»(ref-301478-S27132323142008101700000) .
  1. Remove the front fasica. Refer to «Front Bumper Fascia Replacement»(ref-301478-S27132323142008101700000) .
  2. Remove the upper radiator air deflector.
  1. Install the upper radiator air deflector.
  2. Install the front fasica. Refer to «Front Bumper Fascia Replacement»(ref-301478-S27132323142008101700000) .
  1. Turn the ignition OFF.
  2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  4. Disconnect the coolant heater cord from the coolant heater.
  5. Remove the coolant heater.
  1. Install the coolant heater.
  2. Connect the coolant heater cord to the coolant heater.
  3. Lower the vehicle.
  4. Refill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  2. Disconnect the engine coolant heater cord (1) from the engine coolant heater.
  3. Remove the engine coolant heater.
  4. Clean the engine coolant heater opening.
  1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant heater, if necessary.
  2. Install the engine coolant heater. Tighten: Tighten the coolant heater to 60 N.m (44 lb ft).
  3. Connect the engine coolant heater cord (1) to the engine coolant heater.
  4. Lower the vehicle.
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-301507-S13982568612008101700000) or «Cooling System Draining and Filling (GE 47716 Fill)»(ref-301507-S12163304372008101700000) .
  6. Inspect for leaks.
  1. Raise and support vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  2. Disconnect the coolant heater cord (1).
  3. Remove the coolant heater bolt.
  4. Remove the coolant heater.
  1. Install the coolant heater.
  2. Install the coolant heater bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Connect the coolant heater cord (1).
  4. Lower the vehicle.
  1. Disconnect the engine coolant heater cord (1).
  2. Remove the heater cord retaining clip from the front fender.
  1. Install the heater cord retaining clip to the front fender.
  2. Connect the engine coolant heater cord (1).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  2. Disconnect the engine coolant heater cord (1) from the engine coolant heater.
  3. Lower the vehicle.
  4. Remove the coolant heater cord clip from the transaxle bracket.
  5. Remove the coolant heater cord from the shock tower and the battery tray.
  1. Install the coolant heater cord between the shock tower and the battery tray.
  2. Install the coolant heater cord clip to the transaxle bracket.
  3. Raise and support the vehicle.
  4. Connect the engine coolant heater cord (1) to the engine coolant heater.
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  2. Disconnect the coolant heater power supply cord from the coolant heater (1).
  3. Disconnect the coolant heater cord clip (1).
  4. Lower the vehicle.
  5. Remove the coolant heater cord clip (1) from the heater cord.
  6. Remove the coolant heater cord from the vehicle.
  1. Position the coolant heater power supply cord between the strut tower and battery tray.
  2. Install the coolant heater cord clip (1) to the heater cord.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-301499-S33480567202008101700000) .
  4. Route the coolant heater cord along the engine wiring harness conduit.
  5. Connect the coolant heater cord to the coolant heater (1).
  6. Secure the coolant heater cord clip (1).
  7. Lower the vehicle.

Scheme 18

Scheme 18: Cooling Fan Description and Operation
Scheme 18: Cooling Fan Description and Operation

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a Series/Parallel configuration that allows the engine control module (ECM) to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood fuse block.

During low speed operation, the ECM supplies the ground path for the low speed fan relay, which is Cool/Fan 1 Relay 28 through the low speed cooling fan relay control circuit. This energizes the low speed fan relay coil, closes the relay contacts, and supplies battery positive voltage from the Cool/Fan 1 Fuse 17 through the cooling fan motor supply voltage circuit to the left cooling fan. The ground path for the left cooling fan is through the Series/Parallel relay, which is the cool SER/PAR relay 29, and the right cooling fan. The result is a series circuit with both fans running at low speed.

During high speed operation, the ECM supplies the ground path for the low speed fan relay through the low speed cooling fan relay control circuit. The ECM supplies a ground path for the high speed fan relay, which is Cool/Fan 2 Relay 30, and the Series/Parallel relay through the high speed cooling fan relay control circuit. This energizes the Series/Parallel relay, closes the relay contacts, and provides a ground path for the left cooling fan. At the same time the high fan speed relay coil is energized, the relay contacts close to provide battery positive voltage from the Cool/Fan 2 Fuse 18 on the cooling fan motor supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have their own ground path. The result is a parallel circuit with both fans running at high speed.

When the request for fan activation is withdrawn, the fan may not turn OFF until the ignition switch is moved to the OFF position or the vehicle speed exceeds approximately 10 mph. This is to prevent a fan from cycling ON and OFF excessively at idle.

When the request for fan activation is withdrawn, the fan may not turn OFF until the ignition switch is moved to the OFF position, or the vehicle speed exceeds approximately 16 km/h (10 mph). This is to prevent a fan from cycling ON and OFF excessively at idle.

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