Engine Cooling System Saturn Sky I final

Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers

Scheme 1

Scheme 2

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

Diagnostic Instructions

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

Diagnostic Fault Information

Circuit/System Description

The engine control module (ECM) grounds the low speed relay, which is relay 1, and the high speed relay, which is relay 2, control circuits through an internal solid state device called a driver. The primary function of the driver is to supply the ground for the component being controlled. Each driver has a fault line that is monitored by the ECM. When the ECM is commanding a component ON, the voltage potential of the control circuit should be low, near 0 volts. When the ECM is commanding the control circuit to a component OFF, the voltage potential of the circuit should be high, near battery voltage. If the ECM detects that the actual state of the control circuit does not match the expected state, a DTC will set.

Conditions for Running the DTC

1. The ignition is ON.
2. The system voltage is between 9-18 volts.

Conditions for Setting the DTC

1. An improper voltage level has been detected on the cooling fan relay control circuit.
2. The condition must be present for a minimum of 30 seconds.

Action Taken When the DTC Sets

1. DTC P0480 is a Type B DTC.
2. DTC P0481 is a Type B DTC.

Conditions for Clearing the DTC

1. DTC P0480 is a Type B DTC.
2. DTC P0481 is a Type B DTC.

Reference Information

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Electrical Center Identification Views»(/saturn/sky/i-final-2010-2010/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views)
4. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
5. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

Verify cooling fan operation using the scan tool commands listed below

1. Fan Relay 1 ON and Fan Relay 2 OFF-Fan runs at low speed.
2. Fan Relay 1 OFF and Fan Relay 2 ON-Fan runs at high speed.

Circuit/System Testing

1. Ignition OFF, disconnect the affected relay.
2. Verify that a test lamp illuminates between the B+ circuit terminal listed below and ground: Cool Fan Relay, terminal 85 Cool Fan 2 Relay, terminal 86 If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test the control circuit terminal listed below for a short to ground. If the circuit tests normal, replace the relay. Cool Fan Relay, terminal 85 Cool Fan 2 Relay, terminal 86
3. Test for 70-110 ohms between terminal 85 and terminal 86 of the relay. If not within the specified range, replace the relay.
4. Test for 0.0A with a DMM connected in series with the relay coil between circuit terminal 85 and circuit terminal 86 at the relay connector. If more than the specified value, test the control circuit terminal listed below for a short to ground. If the circuit tests normal, replace the ECM. Cool Fan Relay, terminal 85 Cool Fan 2 Relay, terminal 86
5. Command the relay ON with a scan tool. Verify that the DMM indicates more than 100 mA. If not the specified range, test the control circuit terminal listed below for an open/high resistance. If the circuit tests normal, replace the ECM. Cool Fan Relay, terminal 85 Cool Fan 2 Relay, terminal 86
6. If all circuits and the ECM test normal, replace the affected relay.

Repair Procedures

Cooling Fan and Shroud Replacement

Repair Verification

Ignition ON, command the relay ON and OFF with a scan tool. Feel or listen to verify that the relay turns ON and OFF with each command.

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The engine cooling fan is a variable speed fan. The engine control module (ECM) controls the fan speed by sending a pulse width modulated (PWM) signal to the cooling fan control module. The cooling fan control module varies the voltage drop across the engine cooling fan motor in relation to the pulse width modulated signal. The cooling fan speed can be adjusted from 10 percent to 90 percent duty cycle. 90-94 percent is considered high speed fan.

The ECM monitors the voltage on the cooling fan speed control circuit driver output. Voltage is near B+ when the driver is OFF, and near ground when the driver is ON. If the difference between the actual and expected voltage exceeds a calibrated value, a DTC will set.

1. The engine speed is more than 80 RPM.
2. The system voltage is between 10-18 volts.

P0480

The ECM detects 0 voltage on the output during commanded transitions.

P0691

The ECM detects low voltage on the output while commanded OFF.

P0692

The ECM detects high voltage on the output while commanded ON.

DTC P0480, P0691, and P0692 are Type B DTCs.

DTC P0480, P0691, and P0692 are Type B DTCs.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
4. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)
5. «Electrical Center Identification Views»(/saturn/sky/i-final-2010-2010/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.

1. Ignition OFF, disconnect the cooling fan speed control module.
2. Measure duty cycle with a DMM, set to trigger on the positive slope, between the cooling fan speed control circuit terminal 4 and ground.
3. Ignition ON, command the cooling fan speed from 10-100 percent with a scan tool while observing the DMM. The DMM should transition from 5-85 percent. If the DMM does not transition correctly, test the cooling fan speed control circuit for an open/high resistance, a short to voltage or a short to ground. If the circuit tests normal, replace the ECM.
4. If the ECM and the control circuit test normal, replace the cooling fan assembly.

1. «Cooling Fan and Shroud Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Control Module References»(/saturn/sky/i-final-2010-2010/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for replacement, setup, and programming

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.

Symptoms - Engine Cooling (2.0L)

Note. Review the system operation in order to familiarize yourself with the system functions. Refer to Cooling System Description and Operation .

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the Cooling System. Refer to «Checking Aftermarket Accessories»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__checking-aftermarket-accessories) .
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Inspect the surge tank reservoir for the proper coolant level.

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections .

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Cooling Fan Always On (2.0)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan Always On (2.4)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling Fan Inoperative (2.0)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan Inoperative (2.4)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Overheating»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating)
4. «Loss of Coolant»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant)
5. «Thermostat Diagnosis»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
6. «Engine Fails To Reach Normal Operating Temperature»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__engine-fails-to-reach-normal-operating)

Important Preliminary Inspections Before Starting

Before using the Symptom diagnosis, perform the following

1. Perform «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) and verify all of the following items: Ensure that the engine control module (ECM) and indicator lamp are operating correctly. Ensure that there are no diagnostic trouble codes (DTCs) that are stored. Scan tool data is within a normal operating range. Refer to «Control Module References»(/saturn/sky/i-final-2010-2010/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for scan tool information.
2. Verify the customer concern.
3. Perform the Visual/Physical Inspection in this section. The visual/physical inspection is extremely important, and can lead to correcting a condition without additional testing. It may also help reveal the cause of an intermittent condition.
4. Locate the correct symptom. Perform the tests and inspections associated with the symptom.

Review the system operation in order to familiarize yourself with the system functions. Refer to Cooling Fan Description and Operation .

Several of the symptom procedures call for a careful visual and physical inspection. This can lead to correcting a condition without further tests and can save time. This inspection should include the following areas

1. Ensure that the control module grounds are clean, tight, and correctly located.
2. Inspect cooling system hoses and pipes for splits, kinks, and proper connections. Inspect thoroughly for any type of a leak or a restriction.
3. Inspect for a dirty or restricted radiator and HVAC condenser.
4. Inspect for aftermarket devices which could affect the operation of the Cooling System.
5. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
6. Inspect the surge tank reservoir for the proper coolant level.

Identifying Intermittent Conditions

Many intermittent conditions occur with harness or connector movement due to engine torque, rough pavement, vibration or physical movement of a component. Refer to the following for a list to help determine an intermittent condition

1. Moisture and water intrusion in connectors, terminals, and components
2. Connector mating
3. Terminal contact
4. High circuit or component resistance-High resistance can include any resistance, regardless of the amount, which can interrupt the operation of the component.
5. Harness that is located too tight, or chaffed circuits
6. High or low ambient temperature
7. High or low engine coolant temperatures
8. High underhood temperatures
9. Heat build up in component or circuit due to circuit resistance, poor terminal contact, or high electrical load
10. High or low system voltage
11. High vehicle load conditions
12. Rough road surface
13. Electro-magnetic interference (EMI)/circuit interference from relays, solenoids or other electrical surge
14. Incorrect installation of non-factory, aftermarket, and after factory add on accessories

If an intermittent is determined, refer to Testing for Intermittent Conditions and Poor Connections for specific strategies in diagnosing intermittent conditions.

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Cooling Fan Always On (2.0)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan Always On (2.4)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling Fan Inoperative (2.0)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan Inoperative (2.4)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Overheating»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating)
4. «Loss of Coolant»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant)
5. «Thermostat Diagnosis»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
6. «Engine Fails To Reach Normal Operating Temperature»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__engine-fails-to-reach-normal-operating)

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The low engine coolant level indicator lamp on the instrument panel cluster (IPC) is controlled by the body control module (BCM) through the low speed GM LAN Serial Data circuit. When the engine coolant level switch is open for 30 seconds or longer indicating low coolant, the BCM will signal the IPC to turn ON the Low Coolant Indicator lamp. The lamp will also illuminate for approximately 3 seconds during the display test at the start of each ignition cycle.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling System Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
4. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)

Scan Tool Reference

Control Module References for scan tool information

1. Ignition OFF, verify the radiator surge tank is filled to the correct level, with engine coolant.
2. Ignition ON, observe the scan tool coolant level parameter. The parameter should display OK
3. Command the instrument cluster indicators ON and OFF with a scan tool. The low coolant indicator lamp should turn ON and OFF as commanded. Refer to «Cooling System Description and Operation»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
4. The low coolant indicator should be OFF with the engine coolant at the correct level.

Note. Circuit/System Verification must be performed before performing the Circuit/System Testing.

1. Ignition OFF, disconnect the harness connector at the B33 coolant level switch.
2. Test for less than 5 ohms between the ground circuit terminal B and ground. If greater than the specified range, test the ground circuit for an open/high resistance.
3. Ignition ON, verify the scan tool coolant level switch parameter reads LOW. If not the specified value, test the signal circuit terminal A for a short to ground. If the circuit tests normal, replace the K9 BCM.
4. Install a 3 A fused jumper wire between the signal circuit terminal A and the ground circuit terminal B. Verify the scan tool coolant level parameter displays OK. If not the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the K9 BCM.
5. If all circuits test normal, test or replace the B33 coolant level switch.

Component Testing

1. Ignition OFF, disconnect the harness connector at the B33 coolant level switch.
2. Test for infinite resistance between the signal terminal A and the ground circuit terminal B with the switch in the open position. If not the specified value, replace the B33 switch.
3. Test for less than 5 ohms between the signal terminal A and the ground circuit terminal B with the switch in the closed position. If greater than the specified range, replace the B33 switch.

1. «Radiator Surge Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Control Module References»(/saturn/sky/i-final-2010-2010/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for ECM replacement, setup, and programming

Verify that the low coolant indicator is OFF with the engine coolant at the correct level.

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The engine cooling fan is a variable speed fan. The engine control module (ECM) controls the fan speed by sending a pulse width modulated (PWM) signal to the cooling fan control module. The cooling fan control module varies the voltage drop across the engine cooling fan motor in relation to the pulse width modulated signal. The cooling fan speed can be adjusted from 10 percent to 90 percent duty cycle. 90-94 percent is considered high speed fan.

The ECM monitors the voltage on the cooling fan speed control circuit driver output. Voltage is near B+ when the driver is OFF, and near ground when the driver is ON. If the difference between the actual and expected voltage exceeds a calibrated value, a DTC will set.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
4. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. If DTCs P0480, P0691, or P0692 are set, perform that diagnostic first.
2. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
3. Ignition ON, observe that the fan is not activated. If the fan is activated, replace the cooling fan assembly.

Perform the Cooling Fan and Shroud Replacement after completing the diagnostic procedure.

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, observe that the fan is not activated.

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The engine control module (ECM) grounds the low speed relay, which is relay 1, and the high speed relay, which is relay 2, control circuits through an internal solid state device called a driver. The primary function of the driver is to supply the ground for the component being controlled. Each driver has a fault line that is monitored by the ECM. When the ECM is commanding a component ON, the voltage potential of the control circuit should be low, near 0 volts. When the ECM is commanding the control circuit to a component OFF, the voltage potential of the circuit should be high, near battery voltage. If the ECM detects that the actual state of the control circuit does not match the expected state, a DTC will set.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
4. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. If DTCs P0480 or P0481 are set, perform those diagnostics first.
2. Ignition ON, verify with a scan tool that the control module is not commanding fan activation.
3. Ignition ON, observe that the fan is not activated.

1. Ignition ON, disconnect the cool fan relay. Observe that the fan is ON. If OFF, replace the relay.
2. Disconnect the cool fan 2 relay. Observe that the fan is ON. If OFF, replace the relay.
3. Test the relay control circuit terminals listed below for a short to voltage: Cool Fan 2 Relay, terminal 87 Cool Fan 2 Relay, terminal 30

Cooling Fan and Shroud Replacement

Ignition ON, command the relay ON and OFF with a scan tool. Observe to verify that the fan turns ON and OFF with each command.

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The engine cooling fan is a variable speed fan. The engine control module (ECM) controls the fan speed by sending a pulse width modulated (PWM) signal to the cooling fan control module. The cooling fan control module varies the voltage drop across the engine cooling fan motor in relation to the pulse width modulated signal. The cooling fan speed can be adjusted from 10 percent to 90 percent duty cycle. 90-94 percent is considered high speed fan.

The ECM monitors the voltage on the cooling fan speed control circuit driver output. Voltage is near B+ when the driver is OFF, and near ground when the driver is ON. If the difference between the actual and expected voltage exceeds a calibrated value, a DTC will set.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
4. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. If DTCs P0480, P0691, or P0692 are set, perform that diagnostic first.
2. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
3. Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.

1. Ignition OFF, disconnect the cooling fan.
2. Ignition OFF, measure between ground and the cooling fan ground circuit terminal 2 at the engine harness connector for less than 1 ohm of resistance. If more than 1 ohm, test the ground circuit for an open/high resistance.
3. Connect a test lamp between the cooling fan voltage supply circuit terminal 1 and ground. The lamp should illuminate. If the lamp does not illuminate, test the voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, replace the cooling fan assembly.
4. If all circuits test normal, replace the cooling fan assembly.

1. «Cooling Fan and Shroud Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Control Module References»(/saturn/sky/i-final-2010-2010/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for replacement, setup, and programming

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.

1. Perform the «Diagnostic System Check - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The engine control module (ECM) grounds the low speed relay, which is relay 1, and the high speed relay, which is relay 2, control circuits through an internal solid state device called a driver. The primary function of the driver is to supply the ground for the component being controlled. Each driver has a fault line that is monitored by the ECM. When the ECM is commanding a component ON, the voltage potential of the control circuit should be low, near 0 volts. When the ECM is commanding the control circuit to a component OFF, the voltage potential of the circuit should be high, near battery voltage. If the ECM detects that the actual state of the control circuit does not match the expected state, a DTC will set.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
2. «Connector Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures)
4. «Wiring Repairs»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)
5. «Electrical Center Identification Views»(/saturn/sky/i-final-2010-2010/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views)

1. If DTCs P0480 or P0481 are set, perform those diagnostics first.
2. Verify cooling fan operation using the scan tool commands listed below: Fan Relay 1 ON and Fan Relay 2 OFF-Fan runs at low speed. Fan Relay 1 OFF and Fan Relay 2 ON-Fan runs at high speed.

Note. You must perform the Circuit/System Verification before proceeding with Circuit/System Testing.

1. Ignition OFF, disconnect the relays.
2. Verify that a test lamp illuminates between the B+ circuit terminal listed below and ground: Cool Fan Relay, terminal 30 Cool Fan 2 Relay, terminal 87 If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test the control circuit terminal listed below for a short to ground. Cool Fan Relay, terminal 30 Cool Fan 2 Relay, terminal 87
3. One at a time, connect a 30A fused jumper between terminal 30 and terminal 87 at each relay connection and verify fan activation. If the fan does not activate, test the control circuit terminal listed below for an open/high resistance. If the circuit tests normal, test the fan ground circuit terminal A for an open/high resistance. If the circuits test normal, replace the fan. Cool Fan Relay, terminal 30 Cool Fan 2 Relay, terminal 87
4. If the circuits and fans test normal, replace the relay.

Cooling Fan and Shroud Replacement

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, observe that the fan is not activated.

Engine Overheating

Loss of Coolant

Thermostat Test Procedure Using Glycol

Inspect the operation of the thermostat by hanging the thermostat on a hook in a 33 percent glycol solution.

In order to inspect if the thermostat valve is opening properly, perform the following test

1. Completely submerge the thermostat in a glycol solution. The solution should be 11°C (22°F) above the temperature (180° F), indicated on the thermostat valve.
2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should open.

In order to inspect if the thermostat valve is closing properly, perform the following test

1. Completely submerge the thermostat in a glycol solution. The solution should be 6°C (10°F) below the temperature (180° F), indicated on the thermostat valve.
2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should close completely.

Engine Fails To Reach Normal Operating Temperature

Special Tools

1. J 24460-01 Cooling System Pressure Tester. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

Pressure Cap Testing

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Test the pressure cap for the following conditions: Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) . Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions: The pressure cap does not release pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

1. J 24460-01 Cooling System Pressure Tester. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. J 42401 Radiator Cap / Surge Tank Test Adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

Cooling System Leak Testing

1. Remove the pressure cap.
2. Test the operation of the pressure cap. Refer to «Pressure Cap Testing»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__pressure-cap-testing) .
3. Wash the pressure cap mating surface with water.
4. Use the J 24460-01 with J 42401 in order to apply pressure to the cooling system. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) . Do not exceed the pressure cap rating.
5. The cooling system should hold the rated pressure for at least 2 minutes. Observe the gauge for any pressure loss.
6. Repair any leaks as required.

1. J 26568 Coolant and Battery Fluid Tester. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. J 42401 Radiator Pressure Adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

Draining Procedure

1. Remove the pressure cap.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
3. Place a drain pan under the right side lower radiator mount.
4. Open the radiator drain cock.
5. Drain the cooling system.
6. If a complete block drain is required, place a drain pan under the water pump drain.
7. Remove the water pump drain plug (1).
8. Drain the cooling system.
9. Inspect the appearance of the engine coolant for discoloration: Discolored-Follow the flush procedure. Refer to «Flushing»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__flushing) . Normal in appearance-Follow the filling procedure.

Vac-N-Fill Procedure

1. Close the radiator drain cock by hand.
2. Install the water pump drain plug if removed during the draining process (1) and tighten to 22 N.m (16 lb ft).
3. Install J-42401-2 into the surge tank fill neck.
4. Install J-42401-3 to the surge tank fill neck.
5. Attach the Vac N Fill cap to the J-42401-3.
6. Attach the vacuum gauge assembly to the Vac N Fill cap.
7. Attach the fill hose to the barb fitting on the vacuum gauge assembly. Ensure that the valve is closed.
8. Pour the coolant mixture into the graduated reservoir.
9. Place the fill hose in the graduated reservoir.
10. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
11. Attach the venturi assembly to the vacuum tank.
12. Attach a shop air hose to the venturi assembly. Ensure the valve on the venturi assembly is closed.
13. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
14. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
15. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
16. To aid in the fill process, position the graduated reservoir above the surge tank.
17. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
18. Close the valve on the venturi assembly.
19. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss. If vacuum loss is observed, refer to «Loss of Coolant»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant) .
20. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
21. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 10-16.
22. Detach the Vac N Fill cap from the vehicle's coolant fill port.
23. Add coolant to the system as necessary.
24. Inspect the concentration of the coolant mixture using J 26568 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
25. Detach the vacuum hose from the vacuum gauge assembly.
26. Attach the extraction hose to the vacuum hose.
27. Open the valve on the venturi assembly to start a vacuum draw.
28. Use the extraction hose to draw out coolant to the proper level.
29. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.

1. Remove the surge tank cap (1).
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
3. Place a drain pan under the right side lower radiator mount.
4. Open the radiator drain cock.
5. Drain the cooling system.
6. If a complete block drain is required, place a drain pan under the water pump drain.
7. Remove the water pump drain plug (1).
8. Drain the cooling system.
9. Inspect the appearance of the engine coolant for discoloration: Discolored-Follow the flush procedure. Refer to «Flushing»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__flushing) . Normal in appearance-Follow the filling procedure.

Filling Procedure

1. Close the radiator drain cock by hand.
2. Install the water pump drain plug (1) if removed during the draining process. Tighten: Tighten the plug to 22 N.m (16 lb ft).
3. Lower the vehicle.
4. Disconnect the coolant level sensor electrical connector.
5. Remove and discard the surge tank retainer (2).
6. Loosen surge tank nut (3).
7. Raise and support surge tank approximately 350 mm (13.75 in) above the surge tank bracket.
8. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system until the coolant level reaches and maintains slightly above the cold fill line on the surge tank. Refer to «Approximate Fluid Capacities»(/saturn/sky/i-final-2010-2010/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) .
9. Position the surge tank back on the surge tank bracket.
10. Install a new surge tank retainer (2).
11. Install the surge tank nut (3). Tighten: Tighten the nut to 9 N.m (80 lb in).
12. Connect the coolant level sensor electrical connector.
13. Start the engine and idle.
14. Install surge tank cap (1).
15. Run the engine at 2,000-2,500 RPM for 3 minutes.
16. Allow the engine to idle for 30 seconds.
17. Shut the engine off.
18. Top off the coolant as necessary.
19. Inspect the cooling system for leaks.
20. Rinse away any excess coolant from the engine and the engine compartment.

1. Remove the surge tank cap (1).
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
3. Place a drain pan under the right side lower radiator mount.
4. Open the radiator drain cock.
5. Drain the cooling system.
6. If a complete block drain is required, place a pan under the water pump drain.
7. Remove the water pump drain plug (1).
8. Drain the cooling system.
9. Inspect the appearance of the engine coolant for discoloration: Discolored-Follow the flush procedure. Refer to «Flushing»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system__flushing) . Normal in appearance-Follow the filling procedure.

1. Close the radiator drain cock by hand.
2. Install the water pump drain plug if removed during the draining process (1) and tighten to 22 N.m (16 lb ft).
3. Lower the vehicle.
4. Remove the intake cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
5. Place rags or absorbent material around the surge tank air bleed hose connection (1).
6. Release the hose clamp at the surge tank air bleed hose connection (1) and disconnect the hose from the fitting.
7. Disconnect the coolant level sensor electrical connector.
8. Remove the surge tank retainer (2).
9. Remove the surge tank nut (3).
10. Remove the surge tank outlet hose from the wheel retainer clip.
11. Raise and support the surge tank (4) minimum 350 mm (14 in) above the surge tank bracket.
12. Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean, drinkable water to the surge tank until coolant is present at the surge tank air bleed hose fitting.
13. Immediately reinstall the surge tank air bleed hose and clamp to the fitting and clean up any residual coolant.
14. Slowly add the remaining mixture of 50/50 DEX-COOL antifreeze and clean, drinkable water to the surge tank until the coolant level stabilizes approximately 10-15 mm below the COLD FILL mark on the surge tank. The system will fill slowly and may take up to 10 minutes to fill.
15. Position the surge tank back on the surge tank bracket.
16. Install a surge tank retainer or equivalent (2).
17. Install the surge tank nut (3) and tighten to 9 N.m (80 lb in).
18. Connect the coolant level sensor electrical connector.
19. Install the surge tank outlet hose to the wheel retainer clip.
20. Install the surge tank cap (1) onto the surge tank.
21. Loosen the surge tank cap approximately one complete turn so that the cooling system can vent any remaining air pockets.
22. Start the engine.
23. Run the engine at 2,500-3,000 RPM in PARK (P) (Automatic) or NEUTRAL (N) (Manual) with the parking brake on, until the system reaches normal operating temperature and the thermostat opens completely.
24. Reduce engine speed to idle and allow the engine to idle for 5 minutes.
25. Turn off the engine and if necessary, tighten the surge tank cap completely.
26. Allow the engine to cool and the cooling system pressure to decrease.
27. Turn off the engine and allow it to cool and the system pressure to decrease.
28. Remove the surge tank cap and add coolant to the surge tank FULL COLD mark as necessary.
29. Repeat steps 21 through 28 once more.
30. Install the intake cover.
31. Inspect the cooling system for leaks.
32. Turn ON the blower motor to ensure adequate heating performance.
33. Rinse away any excess coolant from the engine and the engine compartment.
34. Rinse away any excess coolant from the engine and the engine compartment.

Flushing

When the cooling system becomes contaminated, the cooling system should be flushed thoroughly to remove the contaminants before the engine is seriously damaged.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the surge tank. Refer to «Radiator Surge Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Clean and flush the surge tank with clean, drinkable water.
4. Install the surge tank. Refer to «Radiator Surge Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Follow the drain and fill procedure using only clean, drinkable water. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Run the engine for 20 minutes.
7. Stop the engine.
8. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Repeat the procedure if necessary, until the fluid is nearly colorless.
10. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

Radiator Cleaning

1. Some conditions may require the use of warm water and a mild detergent.
2. Clean the A/C condenser fins.
3. Clean between the A/C condenser and radiator.
4. Clean the radiator cooling fins.
5. Straighten any damaged cooling fins.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Removal Procedure

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
2. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Reposition the radiator surge tank hose clamp (1) at the turbocharger coolant feed pipe fitting.
4. Remove the radiator surge tank hose from the turbocharger coolant feed pipe fitting and reposition out of the way.
5. Remove the charge air bypass valve solenoid tube from the turbocharger coolant feed pipe clips (4).
6. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
7. Remove the turbocharger coolant feed pipe fitting (2) from the cylinder head.
8. Remove the turbocharger coolant feed pipe bracket bolt (3) from the cylinder head.
9. Remove the turbocharger coolant feed pipe clips from the camshaft cover and remove the turbocharger coolant feed pipe from the vehicle.
10. Remove the two Christmas tree type retainers.
11. Remove the gaskets from both banjo fittings on the turbocharger coolant feed pipe.

Installation Procedure

1. Install NEW gaskets to both banjo fittings on the turbocharger coolant feed pipe.
2. Install the two Christmas tree type retainers.
3. Position the turbocharger coolant feed pipe to the engine and install the clips to the camshaft cover.
4. Install the turbocharger coolant feed pipe fitting (2) to the cylinder head. Tighten: Tighten the fitting to 35 N.m (26 lb ft).
5. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
6. Install the coolant feed pipe bracket bolt (3) to the cylinder head. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Install the charge air bypass valve solenoid tube to the turbocharger coolant feed pipe clips (4).
8. Position and install the radiator surge tank hose to the turbocharger coolant feed pipe fitting.
9. Position the radiator surge tank hose clamp (1) at the turbocharger coolant feed pipe fitting.
10. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
11. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
3. Remove the turbocharger coolant return pipe bolt at the turbocharger.
4. Remove the turbocharger coolant return pipe bolt at the thermostat housing.
5. Remove the gaskets from both banjo fittings on the turbocharger coolant return pipe.

1. Install NEW gaskets to both banjo fittings on the turbocharger coolant return pipe.
2. Install the turbocharger coolant return pipe bolt at the turbocharger. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
3. Install the turbocharger coolant return pipe bolt at the thermostat housing. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
4. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
5. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt. Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
3. Lower the vehicle.
4. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
5. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
6. Remove the ECT sensor, if necessary.
7. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
8. Remove the radiator outlet hose from the thermostat housing and reposition out of the way.
9. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
10. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
11. Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
12. Remove the thermostat housing bolts.
13. Remove the thermostat housing from the vehicle.
14. Remove the water transfer pipe from the thermostat housing, if necessary.
15. Remove and discard the water transfer pipe O-ring seals, if necessary.
16. Remove the thermostat housing cover bolts and cover, if necessary.
17. Remove the thermostat, if necessary.
18. Remove and discard the thermostat housing O-ring seal, if necessary.
19. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
2. Install the thermostat, if necessary.
3. Install the thermostat housing 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 while the vehicle is lowered.
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
7. Install NEW O-ring seals onto the water feed pipe.
8. Install the water feed pipe into the thermostat housing aligning locator tab.
9. Align the water pipe to water pump.
10. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
11. Lower the vehicle.
12. Position the thermostat housing against the engine.
13. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
14. Connect the heater inlet (2) and outlet (1) hoses to the thermostat housing pipes.
15. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
16. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
17. Install the radiator outlet hose to the thermostat housing.
18. Position the radiator outlet hose clamp (2) at the thermostat housing.
19. If reinstalling the old sensor, coat the threads with sealant. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
20. Install the ECT sensor, if necessary. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
21. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
22. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
23. Verify the drain plugs at the radiator and water pump are tightened.
24. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
25. Lower the vehicle.
26. Inspect for any leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt. Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
3. Lower the vehicle.
4. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
6. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
7. Remove the ECT sensor, if necessary.
8. Reposition the radiator outlet hose clamp at the thermostat housing.
9. Remove the radiator outlet hose from the thermostat housing.
10. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
11. Remove the exhaust heat shield bolts.
12. Remove the exhaust heat shield.
13. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
14. Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
15. Remove the thermostat housing bolts.
16. Remove the thermostat housing from the vehicle.
17. Remove the water transfer pipe from the thermostat housing, if necessary.
18. Remove and discard the water transfer pipe O-ring seals, if necessary.
19. Remove the thermostat housing cover bolts and cover, if necessary.
20. Remove the thermostat, if necessary.
21. Remove and discard the thermostat housing O-ring seal, if necessary.
22. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
2. Install the thermostat, if necessary.
3. Install the thermostat housing 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 while the vehicle is lowered.
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
7. Install NEW O-ring seals onto the water feed pipe.
8. Install the water feed pipe into the thermostat housing aligning locator tab.
9. Align the water pipe to water pump.
10. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
11. Lower the vehicle.
12. Position the thermostat housing against the engine.
13. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
14. Connect the heater inlet (2) and outlet (1) hoses to the thermostat housing pipes.
15. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
16. Install the exhaust heat shield.
17. Install the exhaust heat shield bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
18. Install the radiator outlet hose to the thermostat housing.
19. Reposition the radiator outlet hose clamp at the thermostat housing.
20. Install the radiator outlet hose clip (1) to the outlet hose bracket.
21. If reinstalling the old sensor, coat the threads with sealant. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
22. Install the ECT sensor, if necessary. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
23. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
24. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
25. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
26. Verify the drain plugs at the radiator and water pump are tightened.
27. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
28. Lower the vehicle.
29. Inspect for any leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
3. Reposition the radiator outlet hose clamp at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.
5. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
6. Remove the thermostat housing cover bolts and cover.
7. Remove the thermostat.
8. Remove and discard the thermostat housing O-ring seal.

1. Install a NEW thermostat housing cover O-ring seal onto the housing.
2. Install the thermostat.
3. Install the thermostat housing cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the radiator outlet hose to the thermostat housing.
5. Reposition the radiator outlet hose clamp at the thermostat housing.
6. Install the radiator outlet hose clip (1) to the outlet hose bracket.
7. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
3. Reposition the radiator outlet hose clamp (1) at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.
5. Remove the thermostat housing cover bolts and cover.
6. Remove the thermostat.
7. Remove and discard the thermostat housing O-ring seal.

1. Install a NEW thermostat housing cover O-ring seal onto the housing.
2. Install the thermostat.
3. Install the thermostat housing cover and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the radiator outlet hose to the thermostat housing.
5. Reposition the radiator outlet hose clamp (1) at the thermostat housing.
6. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
7. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

J 43651 Water Pump Holding Tool. See Special Tools .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
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»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
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 turbocharger oil feed pipe. Refer to «Turbocharger Oil Feed Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle)
10. Remove the 2 water pump bolts (1).
11. Remove the rear 2 water pump bolts (1).
12. Remove the water pump (1).
13. 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 bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Tighten the water pump sprocket bolts last. Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the turbocharger oil feed pipe. Refer to «Turbocharger Oil Feed Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle)
7. Remove the J 43651 (1). See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

J-43651: Water Pump Holding Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
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: holding tool into position.
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 (1).
10. Remove the rear 2 water pump bolts.
11. Remove the water pump.
12. If replacing the water pump, remove the water pump rear cover bolts (1) and nut (2).
13. Remove and discard the water pump O-ring seal.

1. Install a NEW water pump O-ring seal.
2. If replacing the water pump, transfer the rear water pump cover (3) to the NEW water pump and tighten the bolts (1) and nut (2) to 25 N.m (18 lb ft).
3. Using the guide pin, align the pin with the water pump holding tool.
4. Position the water pump against the engine block and hand tighten the water pump bolts (1).
5. Install 2 inner water pump sprocket bolts (1). After the 2 bolts are snug, remove the guide pin and install the 3rd bolt and tighten to 25 N.m (18 lb ft).
6. Tighten the rear water pump bolts (1) to 10 N.m (89 lb in).
7. Remove the J-43651: holding tool.
8. Install the water pump access plate and bolts. Tighten to 10 N.m (89 lb in).
9. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

Charge Air Cooler Cleaning

1. Some conditions may require the use of warm water and a mild detergent.
2. Clean the charge air cooler fins.
3. Clean between the charge air cooler and condenser.
4. Straighten any damaged cooling fins.

Radiator Drain Cock Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
2. Place a drain pan under the right side lower radiator mount.
3. Loosen the radiator drain cock.

1. Tighten the radiator drain cock. Tighten the radiator drain cock by hand only.
2. Lower the vehicle.
3. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Cooling Fan Control 2.0L

The engine cooling fan is a variable speed fan. The engine control module (ECM) controls the fan speed by sending a pulse width modulated (PWM) signal to the cooling fan control module. The cooling fan control module varies the voltage drop across the engine cooling fan motor in relation to the PWM signal. The cooling fan speed can be adjusted from 10 percent to 94 percent duty cycle. 94 percent is considered high speed fan.

Cooling Fan Control 2.4L

The engine cooling fan system consists of one cooling fan and two relays. The cooling fan motor assembly contains an internal resistor that allows the cooling fan to be operated at a reduced speed, and at a high speed. Voltage is supplied to each relay through two individual 30 amp fuses. The engine control module (ECM) controls the low speed fan operation by grounding the Fan 1 control circuit. When the COOL FAN, which is the low speed relay, is energized, voltage is supplied to the cooling fan through the internal resistor. The ECM controls the high speed fan operation by grounding the Fan 2 relay control circuit. When the COOL FAN 2 Relay, which is the high speed relay, is energized, voltage is supplied directly to the cooling fan. The cooling fan motor is grounded with a dedicated ground circuit.

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.

Cooling Fan Control

The engine cooling fan system consists of one cooling fan and two relays. The cooling fan has 2 windings in the motor, one winding is for low speed and the other winding is for high speed. Voltage is supplied to the relays from the 30 A cooling fan 1 and 30 A cooling fan 2 fuses. The engine control module (ECM) controls the low speed fan operation by grounding the cool fan 1 relay control circuit. When the cooling fan 1 relay is energized, voltage is delivered to the cooling fan low speed winding. The ECM controls the high speed fan operation by grounding the cool fan 2 relay control circuit. When the cooling fan 2 relay is energized, voltage is delivered to the cooling fan high speed winding. The cooling fan motor is grounded through its own ground circuit.

The PCM commands Low Speed Fans ON under the following conditions

1. Engine coolant temperature (ECT) exceeds approximately 106°C (223°F).
2. A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
3. After the vehicle is shut off, the ECT at key-off is greater than 140°C (284°F) and system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.

The PCM commands High Speed Fans ON under the following conditions

1. ECT reaches 110°C (230°F).
2. A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
3. When certain DTCs set

Engine Coolant Indicator(s)

The instrument panel cluster (IPC) illuminates the low coolant warning indicator when any of the following occur

1. The body control module (BCM) detects a low coolant level condition for at least 30 seconds. The IPC receives a class 2 message from the BCM requesting illumination.
2. The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds.

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

Charge Air Cooling System (LNF Only)

The charge air cooling systems function is to reduce the temperature of the air charge that is heated during the turbocharged process which improves the efficiency of the turbocharged system. The charge air cooling system is a air-to-air system that uses a charge air cooling radiator located in front of the fan shroud to cool the air charge.

Cooling Cycle (LE5)

Coolant from the water pump is circulated through the water jackets in the cylinder block where the coolant absorbs the released heat.

The coolant also flows through the cylinder head gasket openings and into the cylinder head. The coolant flows through the water jackets surrounding the combustion chambers and valve seats where the coolant absorbs additional heat.

Coolant flows from the water pump into the radiator inlet port located on top of the radiator. From the radiator outlet, the coolant flows to the surge tank and to the thermostat assembly. The flow of coolant will either be stopped at the thermostat until the engine reaches normal operating temperature, or it will flow through the thermostat and back through the cooling system to the radiator where it will be cooled. At this point, the coolant flow cycle is completed.

Some coolant flow through the engine is directed through the heater core, then back to the engine. This provides the passenger compartment with heat and defrosting capability as the cooling system warms up.

Efficient operation of the cooling system requires proper functioning of all cooling system components.

Cooling Cycle (LNF)

Coolant from the water pump is circulated through the water jackets in the cylinder block and absorbs the released heat.

The coolant then flows through the cylinder head gasket openings and into the cylinder head. The coolant flows through the water jackets surrounding the combustion chambers and valve seats where the coolant absorbs additional heat.

Coolant flows from the water pump outlet to the radiator inlet port located on top of the radiator. From the radiator outlet, the coolant flows to both the engine oil cooler (EOC) and the thermostat housing.

1. At the EOC, coolant flows through the EOC and is then directed to the thermostat housing and the surge tank.
2. At the thermostat housing the flow of coolant will either be stopped by the thermostat until the engine reaches normal operating temperature, or it will flow through the thermostat and back through the cooling system to the radiator where it will be cooled.

Some coolant flow through the engine is directed through the heater core, then back to the engine. This provides the passenger compartment with heat and defrosting capability as the cooling system warms up.

Coolant flow is also directed to the turbocharger assembly to aid the turbocharger in temperature control and system performance. At this point, the coolant flow cycle is complete.

Efficient operation of the cooling system requires proper functioning of all cooling system components.

Coolant

The engine coolant is a solution made up of a 50-50 mixture of DEX-COOL and suitable drinking water. The coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the atmosphere.

Radiator

The radiator is a heat exchanger. It consists of a core and two tanks. The aluminum core is a tube and fin crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere.

The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core.

The radiator also has a drain cock located in the bottom of the right hand tank. The drain cock unit includes the drain cock and drain cock seal.

The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.

Pressure Cap

The pressure cap seals the cooling system. It contains a blow off or pressure valve and a vacuum or atmospheric valve. The pressure valve is held against its seat by a spring, which protects the radiator from excessive cooling system pressure. The vacuum valve is held against its seat by a spring, which permits opening of the valve to relieve vacuum created in the cooling system as it cools off. The vacuum, if not relieved, might cause the radiator and/or coolant hoses to collapse.

The pressure cap allows cooling system pressure to build up as the temperature increases. As the pressure builds, the boiling point of the coolant increases. Engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant is, the faster the heat transfers from the radiator to the cooler, passing air.

The pressure in the cooling system can get too high. When the cooling system pressure exceeds the rating of the pressure cap, it raises the pressure valve, venting the excess pressure.

As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open, allowing outside air into the surge tank. This equalizes the pressure in the cooling system with atmospheric pressure, preventing the radiator and coolant hoses from collapsing.

Surge Tank

The surge tank is a plastic tank that the pressure cap mounts onto. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an air space in the cooling system. The air space allows the coolant to expand and contract. The surge tank also provides a coolant fill point and a central air bleed location. During vehicle use, the coolant heats and expands. The coolant that is displaced by this expansion flows into the surge tank. As the coolant circulates, air is allowed to exit. This is an advantage to the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles.

Air Baffles and Seals

The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent recirculation of hot air for better hot weather cooling and A/C condenser performance.

Water Pump

The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is mounted on the pump shaft and consists of a series of flat or curved blades or vanes on a flat plate. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force.

The impeller shaft is supported by one or more sealed bearings. The sealed bearings never need to be lubricated. Grease cannot leak out, dirt and water cannot get in as long as the seal is not damaged or worn.

The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is driven by the crankshaft via the timing chain.

Thermostat

The thermostat is a coolant flow control component. It's purpose is to help regulate the operating temperature of the engine. It utilizes a temperature sensitive wax-pellet element. The element connects to a valve through a small piston. When the element is heated, it expands and exerts pressure against the small piston. This pressure forces the valve to open. As the element is cooled, it contracts. This contraction allows a spring to push the valve closed.

When the coolant temperature is below the rated thermostat opening temperature, the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up. After the coolant temperature reaches the rated thermostat opening temperature, the thermostat valve will open. The coolant is then allowed to circulate through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system, after it has opened. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.

Engine Oil Cooler

The engine oil cooler (EOC) is an auxiliary heat exchanger located on the left rear side of the engine. Numerous cooling plates inside the EOC help to dissipate heat and control engine oil temperature.

The engine oil pump forces the engine oil through the EOC cooler through an inlet pipe. The engine oil then flows through the EOC where heat is dissipated from the fluid back to the atmosphere. The engine oil is then pumped through the EOC return pipe, back to the engine.

Transmission Oil Cooler

The transmission oil cooler is a heat exchanger. It is located inside the left side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator.

The transmission oil pump, pumps the fluid through the transmission oil cooler line to the transmission oil cooler. The fluid then flows through the cooler where the engine coolant absorbs heat from the fluid. The fluid is then pumped through the transmission oil cooler return line, to the transmission.

Illustration Tool Number/Description J 24460-01 Radiator Pressure Tester J 26568 Coolant and Battery Fluid Tester J 38185 Hose Clamp Pliers J 42220 Universal 12V Leak Detection Lamp J 42401 Radiator Cap/Surge Tank Tester Adapter J 43651 Waterpump Holding Tool

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See also:
• Diagnostic System Check - Vehicle
• Strategy Based Diagnosis
• Diagnostic Procedure Instructions
• Component Connector End Views
• Circuit Testing
• Connector Repairs
• Electrical Center Identification Views
• Testing for Intermittent Conditions and Poor Connections
• Wiring Repairs
• Control Module References
• Checking Aftermarket Accessories
• Engine Coolant Temperature Sensor Replacement
• Moving Parts and Hot Surfaces Warning
• Approximate Fluid Capacities
• Heater Core Replacement
• Engine Coolant/Water in Transmission
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Lower Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Lifting and Jacking the Vehicle
• Fastener Caution
• Intake Manifold Cover Replacement
• Air Inlet Grille Panel Replacement (SKY)
• Air Cleaner Assembly Replacement
• Catalytic Converter Replacement (LE5)
• Adhesives, Fluids, Lubricants, and Sealers
• Intake Manifold Cover Replacement
• DTC P0480 or P0481 (2.4)
• Engine Overheating
• Loss of Coolant
• Engine Fails To Reach Normal Operating Temperature
• Flushing
• Symptoms - Engine Cooling (2.0L)
• Cooling System Leak Testing
• Pressure Cap Testing
• Adhesives, Fluids, Lubricants, and Sealers