Engine Cooling System: Removal & Installation Saturn VUE I

Removal Procedure

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the surge tank inlet hose clamp from the surge tank.
3. Remove the surge tank inlet hose from the surge tank.
4. Remove the surge tank bolts from the vehicle.
5. Lift the surge tank to gain access to the bottom of the tank.
6. Disconnect the low coolant sensor from the surge tank.
7. Remove the surge tank outlet hose clamp from the bottom of the surge tank.
8. Remove the surge tank outlet hose from the bottom of the surge tank.

Installation Procedure

1. Install the surge tank outlet hose to the bottom of the surge tank.
2. Install the surge tank outlet hose clamp to the bottom of the surge tank.
3. Connect the low coolant sensor to the surge tank.
4. Align the surge tank retention tab and lower the surge tank into the vehicle.
5. Install the surge tank bolts to the vehicle. Tighten: Tighten the bolts to 8 N.m (71 lb in).
6. Install the surge tank inlet hose to the surge tank.
7. Install the surge tank inlet hose clamp to the surge tank.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-188785-S11929077392005090200000) in Engine Controls - 2.2L (L61).
3. Remove the surge tank inlet hose clamp from the surge tank.
4. Remove the surge tank inlet hose from the surge tank.
5. Remove the surge tank inlet hose clamp from the engine.
6. Remove the surge tank inlet hose from the engine.
7. Disconnect the surge tank inlet hose retainers from the engine.
8. Remove the surge tank inlet hose from the vehicle.

1. Install the surge tank inlet hose to the vehicle.
2. Connect the surge tank inlet hose retainers to the engine.
3. Install the surge tank inlet hose to the engine.
4. Install the surge tank inlet hose clamp to the engine.
5. Install the surge tank inlet hose to the surge tank.
6. Install the surge tank inlet hose clamp to the surge tank.
7. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-188785-S11929077392005090200000) in Engine Controls - 2.2L (L61).
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Remove the surge tank. Refer to «Surge Tank Replacement»(ref-188798-S22458457372005090200000) .
2. Remove the surge tank outlet hose clamp from the hose to aid in hose routing.
3. Remove the surge tank outlet hose clamp from the engine.
4. Remove the surge tank outlet hose from the engine.
5. Remove the surge tank outlet hose from the vehicle.

1. Install the surge tank outlet hose to the vehicle.
2. Install the surge tank outlet hose to the engine.
3. Install the surge tank outlet hose clamp to the engine.
4. Install the surge tank outlet hose clamp to the hose.
5. Install the surge tank. Refer to «Surge Tank Replacement»(ref-188798-S22458457372005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the radiator inlet hose clamp from the radiator.
3. Remove the radiator inlet hose from the radiator.
4. Remove the surge tank inlet hose from the surge tank.
5. Remove the radiator hose retaining straps from the radiator support.
6. Remove the radiator inlet hose clamp from the engine.
7. Remove the radiator inlet hose from the engine.

1. Install the radiator inlet hose to the engine.
2. Install the radiator inlet hose clamp to the engine.
3. Install the surge tank inlet hose to the surge tank.
4. Install the radiator hose retaining straps to the radiator support.
5. Install the radiator inlet hose to the radiator.
6. Install the radiator inlet hose clamp to the radiator.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the radiator inlet hose clamp from the radiator.
3. Remove the radiator inlet hose from the radiator.
4. Remove the radiator inlet hose clamp from the engine.
5. Remove the radiator inlet hose from the engine.

1. Install the radiator inlet hose to the engine.
2. Install the radiator inlet hose clamp to the engine.
3. Install the radiator inlet hose to the radiator.
4. Install the radiator inlet hose clamp to the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the radiator outlet hose clamp from the engine.
3. Remove the radiator outlet hose from the engine.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
5. Remove the radiator outlet hose clamp from the radiator.
6. Remove the radiator outlet hose from the radiator.

1. Route the radiator outlet hose into the vehicle.
2. Install the radiator outlet hose to the radiator.
3. Install the radiator outlet hose clamp to the radiator.
4. Lower the vehicle.
5. Install the radiator outlet hose to the engine.
6. Install the radiator outlet hose clamp to the engine.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the radiator outlet hose clamp from the radiator.
3. Remove the radiator outlet hose from the radiator.
4. Remove the radiator outlet hose clamp from the engine.
5. Remove the radiator outlet hose from the engine.

1. Install the radiator outlet hose to the engine.
2. Install the radiator outlet hose clamp to the engine.
3. Install the radiator outlet hose to the radiator.
4. Install the radiator outlet hose clamp to the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000)

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.1L.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
3. Remove the throttle body inlet hose clamp and the hose from the coolant pipe.
4. Remove the throttle body inlet hose clamp and the hose from the throttle body and the vehicle.

1. Install the throttle body inlet hose and the hose clamp to the throttle body.
2. Install the throttle body inlet hose and the hose clamp to the coolant pipe.
3. Install the throttle body air inlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.1L.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
5. Inspect for leaks.

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.1L.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
3. Remove the throttle body outlet hose clamp and the hose from the coolant pipe.
4. Remove the throttle body outlet hose clamp and the hose from the throttle body and the vehicle.

1. Install the throttle body outlet hose and the hose clamp to the throttle body.
2. Install the throttle body outlet hose and the hose clamp to the coolant pipe.
3. Install the throttle body air inlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-188786-S05995003882005090200000) in Engine Controls - 3.1L.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
5. Inspect for leaks.

1. Remove the cooling fan and shroud from the vehicle. Refer to «Cooling Fan and Shroud Replacement (L61)»(ref-188798-S33307794722005090200000) or «Cooling Fan and Shroud Replacement (L66)»(ref-188798-S27702411252005090200000) .
2. Place a scribe mark (3) on the fan (2) hub and the motor shaft (1).
3. Remove the fan retaining clip (1) from the motor shaft (2).
4. Discard fan retaining clip (1).
5. Remove the fan (1) from the motor (2).

1. Install the fan (1) to the motor (2).
2. Align the scribe marks (3) previously made on the fan (2) hub and the motor shaft (1).
3. Install a new fan retaining clip (1) to the motor shaft (2). Ensure the retaining clip (1) is fully seated.
4. Install the cooling fan and shroud to the vehicle. Refer to «Cooling Fan and Shroud Replacement (L61)»(ref-188798-S33307794722005090200000) or «Cooling Fan and Shroud Replacement (L66)»(ref-188798-S27702411252005090200000) .

1. Remove the cooling fan and shroud from the vehicle. Refer to «Cooling Fan and Shroud Replacement (L61)»(ref-188798-S33307794722005090200000) or «Cooling Fan and Shroud Replacement (L66)»(ref-188798-S27702411252005090200000) .
2. Place a scribe mark (3) on the fan (2) hub and the motor shaft (1).
3. Remove the fan retaining clip (1) from the motor shaft (2).
4. Discard fan retaining clip (1).
5. Remove the fan (1) from the motor (2).
6. Remove the fan motor screws from the fan shroud.
7. Remove the fan motor from the fan shroud.

1. Install the fan motor to the fan shroud.
2. Install the fan motor screws to the fan shroud. Tighten: Tighten the screws to 8 N.m (71 lb in).
3. Install the fan (1) to the motor (2).
4. Align the scribe marks (3) previously made on the fan (2) hub and the motor shaft (1).
5. Install a new fan retaining clip (1) to the motor shaft (2). Ensure the retaining clip (1) is fully seated.
6. Install the cooling fan and shroud to the vehicle. Refer to «Cooling Fan and Shroud Replacement (L61)»(ref-188798-S33307794722005090200000) or «Cooling Fan and Shroud Replacement (L66)»(ref-188798-S27702411252005090200000) .

1. Remove the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
2. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
3. Disconnect the electrical connector from the fan motor.
4. Unclip the wire harness from the fan assembly.
5. Unclip the transmission cooler lines from the fan assembly.
6. Remove the battery box inlet air duct.
7. Remove the condenser radiator fan module (CRFM) closeout panel retainers from the condenser.
8. Remove the CRFM closeout panel from the condenser.
9. Remove the radiator inlet hose clamp from the radiator.
10. Remove the radiator inlet hose from the radiator.
11. Remove the radiator outlet hose clamp from the radiator.
12. Remove the radiator outlet hose from the radiator.
13. Remove the CRFM mounting bracket bolts from the radiator support.
14. Remove the CRFM mounting brackets from the radiator support.
15. Lift the CRFM assembly from the lower mounts and carefully move the bottom of the assembly rearward while tilting the top forward.
16. Remove the fan assembly bolts from the radiator.
17. Remove the fan assembly from the radiator.

1. Install the fan assembly to the radiator by guiding the lower tabs into the corresponding hooks on the radiator.
2. Install the fan assembly bolts to the radiator. Tighten: Tighten the bolts to 8 N.m (71 lb in).
3. Position the CRFM assembly onto the lower mounts.
4. Install the CRFM mounting brackets to the radiator support.
5. Install the CRFM mounting bracket bolts to the radiator support. Tighten: Tighten the bolts to 8 N.m (71 lb in).
6. Install the radiator outlet hose to the radiator.
7. Install the radiator outlet hose clamp to the radiator.
8. Install the radiator inlet hose to the radiator.
9. Install the radiator inlet hose clamp to the radiator.
10. Install the CRFM closeout panel to the condenser.
11. Install the CRFM closeout panel retainers to the condenser.
12. Install the battery box inlet air duct.
13. Clip the transmission cooler lines to the fan assembly.
14. Clip the engine wire harness to fan assembly.
15. Install the electrical connector to the fan motor.
16. Install the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
17. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Remove the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
2. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
3. Disconnect the electrical connectors from the fan motors.
4. Unclip the wire harness from the fan assembly.
5. Unclip the transmission cooler lines from the fan assembly.
6. Remove the condenser radiator fan module (CRFM) closeout panel retainers from the condenser.
7. Remove the CRFM closeout panel from the condenser.
8. Remove the radiator inlet hose clamp from the radiator.
9. Remove the radiator inlet hose from the radiator.
10. Remove the radiator inlet hose retaining straps from the radiator support.
11. Remove the radiator outlet hose clamp from the radiator.
12. Remove the radiator outlet hose from the radiator.
13. Remove the CRFM mounting bracket bolts from the radiator support.
14. Remove the CRFM mounting brackets from the radiator support.
15. Lift the CRFM assembly from the lower mounts and carefully move the bottom of the assembly rearward while tilting the top forward.
16. Remove the fan assembly bolts from the radiator.
17. Remove the fan assembly from the radiator.

1. Install the fan assembly to the radiator by guiding the lower tabs into the corresponding hooks on the radiator. Install the fan assembly bolts to the radiator. Tighten: Tighten the bolts to 8 N.m (71 lb in).
2. Position the CRFM assembly onto the lower mounts.
3. Install the CRFM mounting brackets to the radiator support.
4. Install the CRFM mounting bracket bolts to the radiator support. Tighten: Tighten the bolts to 8 N.m (71 lb in).
5. Install the radiator outlet hose to the radiator.
6. Install the radiator outlet hose clamp to the radiator.
7. Install the radiator inlet hose to the radiator.
8. Install the radiator inlet hose clamp to the radiator.
9. Install the CRFM closeout panel to the condenser.
10. Install the CRFM closeout panel retainers to the condenser.
11. Clip the transmission cooler lines to the fan assembly.
12. Clip the engine wire harness to fan assembly.
13. Install the electrical connectors to the fan motors.
14. Install the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
15. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the exhaust heat shield bolts.
3. Remove the exhaust heat shield.
4. Raise the vehicle.
5. Drain the coolant from the water pump drain plug.
6. Remove the thermostat cover bolts from the thermostat housing.
7. Remove and discard the thermostat housing O-seal.
8. Remove the water pipe from the water pump assembly.
9. Remove and discard the seals from the water pipe.
10. Remove the inner thermostat sleeve.
11. Remove the thermostat assembly.

1. Install the thermostat cartridge into the thermostat housing while aligning the cartridge tangs up with the thermostat housing bolt holes. This will assure the inner sleeve can be completely installed.
2. Align and insert the inner sleeve notch into the thermostat housing. If the inner sleeve notch is not properly positioned, the sleeve will not completely seat into the housing.
3. Install a new O-seal on the water pipe.
4. Position the water pipe into the water pump assembly.
5. Seat the water feed O-seal by pushing and twisting toward the water pump. Take care not to tear or damage the O-ring.
6. Install the thermostat housing cover to the water pipe. The water feed pipe has a locating tab to assure proper alignment.
7. Install a new thermostat housing cover seal into the recess groove.
8. Position the thermostat housing cover into position.
9. Install the thermostat housing cover bolts. Tighten: Tighten the thermostat housing cover-to-thermostat housing bolts to 10 N.m (89 lb in).
10. Lower the vehicle.
11. Install the exhaust manifold heat shield.
12. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 23 N.m (17 lb ft).
13. Verify the drain valve at the radiator and the water pump are closed.
14. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
15. Verify the repair and inspect for any leaks.

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
3. Remove the thermostat housing.
4. Remove the thermostat.

1. Install the thermostat with housing. Install a new gasket. Position the thermostat with the housing. Apply thread sealant PST 565® to the bolt threads. NOTE: Refer to «Fastener Notice»(ref-188778-S34486324502005090200000) in Cautions and Notices. Install the housing bolts. Tighten: Tighten the thermostat housing bolts 12 N.m (106 lb in).
2. Install the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
3. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical.
2. Remove the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
3. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
5. Remove the ECT sensor.
6. Remove the radiator inlet and outlet hoses from the crossover pipe.
7. Disconnect the wiring harness ground terminal from the crossover pipe.
8. Remove the thermostat housing and thermostat from the crossover pipe.
9. Remove the crossover pipe bolts and crossover pipe.

1. Clean and dry the area before installing new seals.
2. Install the crossover pipe.
3. Install the crossover pipe bolts. Tighten: Tighten the crossover pipe bolts to 22 N.m (16 lb ft).
4. Install the thermostat and thermostat housing. Tighten: Tighten the thermostat housing bolts to 12 N.m (106 lb in).
5. Connect the coolant hoses at the crossover pipe.
6. Connect the wiring harness ground terminal to the crossover pipe. Tighten: Tighten the nut to 12 N.m (106 lb in).
7. Apply thread sealant (Saturn P/N 21485277) Loctite™ 242 threadlocker, or equivalent, to sensor threads.
8. Install the ECT sensor. Tighten: Tighten the ECT sensor to 18 N.m (13 lb ft).
9. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
10. Install the battery. Refer to «Battery Replacement»(ref-188769-S31052717452005090200000) in Engine Electrical.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-188769-S19455074222005090200000) in Engine Electrical. Tighten: Tighten the battery terminal bolt to 17 N.m (13 lb ft).
12. Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the thermostat housing pipe-to-cylinder bolt near the front of the engine.
3. Remove the exhaust manifold heat shield and bolts.
4. Remove the water pump access plate from the front cover.
5. Remove the right hand wheel nuts and wheel assembly.
6. Remove the right hand inner push-pins and splash shield.
7. Drain the coolant from the plug at the bottom of the water pump.
8. Disconnect the engine coolant temperature sensor electrical connector.
9. Remove the thermostat housing bolts.
10. Move the thermostat housing toward the left hand side of the vehicle while twisting the water feed pipe from the rear of the water pump assembly. Leave the coolant hoses and thermostat housing cover connected.
11. Remove the water feed pipe.
12. Discard the water pipe seals.
13. Install the J 43651 into position. See «Special Tools and Equipment»(ref-188798-S26468822222005090200000) .
14. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
15. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
16. Remove the 3 inner water pump sprocket to water pump blots.
17. Remove the 2 water pump assembly bolts.
18. Remove the rear 2 water pump assembly bolts.
19. Remove the water pump assembly and water pump O-seal.

1. Install a new water pump assembly seal.
2. Using the guide pin, align the pin with the water pump holding tool.
3. Position the water pump assembly against the engine block and hand tighten the water pump bolts.
4. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the third bolt. Tighten: Tighten the water pump bolts to 25 N.m (18 lb ft).
5. Tighten the water pump bolts. Tighten: Tighten the water pump sprocket-to-water pump bolts to 10 N.m (89 lb in).
6. Remove the J 43651 . See «Special Tools and Equipment»(ref-188798-S26468822222005090200000) .
7. Install the water pump access plate and bolts. Tighten: Tighten the water pump access bolts-to-front cover to 10 N.m (89 lb in).
8. Install a new O-ring seal on the water feed pipe.
9. Install the thermostat housing to block seal onto the thermostat housing, if damaged.
10. Install the water feed pipe into the water pump assembly.
11. Align the water feed pipe to the thermostat housing assembly.
12. Seat the water feed O-ring seal by pushing and twisting toward the water pump. Take care not to tear or damage the O-ring.
13. The water feed pipe has a locating tab to assure proper alignment.
14. Position the thermostat housing against the engine. Be sure that the thermostat housing pipe is properly positioned against the support bracket near the front of the engine.
15. Install the thermostat housing to block bolts. Tighten: Tighten the thermostat housing-to-block bolts to 10 N.m (89 lb in).
16. Connect the electrical connector to coolant temperature sensor.
17. Install the right hand inner splash shield and push pins.
18. Install the right hand tire assembly and wheel nuts. Tighten: Tighten the wheel nuts to 125 N.m (92 lb ft).
19. Lower the vehicle.
20. Install the thermostat pipe bracket to cylinder head bolt. Tighten: Tighten the thermostat pipe bracket-to-cylinder head bolt to 8 N.m (71 lb in).
21. Install the exhaust manifold heat shield.
22. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 23 N.m (17 lb ft).
23. Verify the drain valves at the radiator and water pump are closed.
24. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
25. Verify the repair and inspect for any leaks.

1. Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the timing belt cover. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) in Engine Mechanical - 3.5L.
3. Remove the water pump assembly bolts.
4. Remove the water pump and O-ring.

1. Clean and block at the water pump mating surface.
2. Install a new water pump O-seal to the water pump.
3. Install the water pump assembly.
4. Install the water pump bolts. Tighten: Tighten the water pump bolts to 12 N.m (18 lb in).
5. Install the timing belt cover. Refer to «Timing Belt Cover Replacement»(ref-188818-S24076870982005090200000) in Engine Mechanical - 3.5L.
6. Fill the coolant system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the radiator. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Unscrew the drain plug from the radiator end tank. Then using a flat-bladed tool, gently pry the plug from the end tank.

1. Install the drain plug into the end tank drain hole by snapping into place. Tighten using a flat-bladed tool.
2. Fill the radiator. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
3. Remove the battery box inlet air duct.
4. Remove the condenser radiator fan module (CRFM) closeout panel retainers from the condenser.
5. Remove the CRFM closeout panel from the condenser.
6. Remove the fan assembly bolts from the radiator.
7. Lift the fan assembly to disengage the lower retention tabs.
8. Position the fan assembly away from the radiator.
9. Lift the condenser while holding the upper retention tabs forward.
10. Position the condenser away from the radiator.
11. Disconnect the transmission cooler liners from the transmission cooler, if equipped.
12. Remove the transmission cooler bolt from the radiator, if equipped.
13. Lift the transmission cooler while holding the upper retention tabs forward, if equipped.
14. Remove the transmission cooler from the vehicle.
15. Remove the CRFM bracket bolts from the radiator support.
16. Remove the CRFM brackets from the radiator.
17. Remove the radiator inlet hose clamp from the radiator.
18. Remove the radiator inlet hose from the radiator.
19. Remove the radiator outlet hose clamp from the radiator.
20. Remove the radiator outlet hose from the radiator.
21. Remove the radiator from the vehicle.
22. Remove the radiator seals from the radiator.

1. Install the radiator seals to the radiator.
2. Install the radiator to the vehicle.
3. Install the radiator outlet hose to the radiator.
4. Install the radiator outlet hose clamp to the radiator.
5. Install the radiator inlet hose to the radiator.
6. Install the radiator inlet hose clamp to the radiator.
7. Install the CRFM bracket to the radiator support.
8. Install the CRFM brackets bolts to the radiator. Tighten: Tighten the bolt to 8 N.m (71 lb in).
9. Install the transmission cooler to the vehicle, if equipped. Press down to engage the upper retention tabs.
10. Install the transmission cooler bolt to the radiator, if equipped. Tighten: Tighten the bolt to 8 N.m (71 lb in).
11. Connect the transmission cooler liners to the transmission cooler, if equipped.
12. Install the condenser to the radiator. Press down to engage the upper retention tabs.
13. Install the fan assembly to the radiator.
14. Install the fan assembly bolts to the radiator. Tighten: Tighten the bolts to 8 N.m (71 lb in).
15. Install the CRFM closeout panel to the condenser.
16. Install the CRFM closeout panel retainers to the condenser.
17. Install the battery box inlet air duct.
18. Install the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
19. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Remove the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
3. Remove the condenser radiator fan module (CRFM) closeout panel retainers from the condenser.
4. Remove the CRFM closeout panel from the condenser.
5. Remove the fan assembly bolts from the radiator.
6. Lift the fan assembly to disengage the lower retention tabs.
7. Position the fan assembly away from the radiator.
8. Lift the condenser while holding the upper retention tabs forward.
9. Position the condenser away from the radiator.
10. Disconnect the transmission cooler liners from the radiator.
11. Remove the CRFM bracket bolts from the radiator support.
12. Remove the CRFM brackets from the radiator.
13. Remove the radiator inlet hose clamp from the radiator.
14. Remove the radiator inlet hose from the radiator.
15. Remove the radiator outlet hose clamp from the radiator.
16. Remove the radiator outlet hose from the radiator.
17. Remove the radiator from the vehicle.
18. Remove the radiator seals from the radiator.

1. Install the radiator seals to the radiator.
2. Install the radiator to the vehicle.
3. Install the radiator outlet hose to the radiator.
4. Install the radiator outlet hose clamp to the radiator.
5. Install the radiator inlet hose to the radiator.
6. Install the radiator inlet hose clamp to the radiator.
7. Install the CRFM bracket to the radiator support.
8. Install the CRFM brackets bolts to the radiator. Tighten: Tighten the bolt to 8 N.m (71 lb in).
9. Connect the transmission cooler liners to the radiator.
10. Install the condenser to the radiator. Press down to engage the upper retention tabs.
11. Install the fan assembly to the radiator.
12. Install the fan assembly bolts to the radiator. Tighten: Tighten the bolts to 8 N.m (71 lb in).
13. Install the CRFM closeout panel to the condenser.
14. Install the CRFM closeout panel retainers to the condenser.
15. Install the front fascia. Refer to «Fascia Replacement - Front Bumper»(ref-188808-S27906573402005090200000) in Bumpers.
16. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Disconnect the coolant heater cord (1).
2. Remove the coolant heater bolt.
3. Remove the coolant heater.

1. Install the coolant heater.
2. Install the coolant heater bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Connect the coolant heater cord (1).

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. Disconnect the coolant heater power supply cord from the coolant heater.
3. Remove the coolant heater and washer from the engine block.

1. Install the washer to the coolant heater.
2. Install the coolant heater into the engine block. Tighten: Tighten the coolant heater to 60 N.m (44 lb ft).
3. Connect the coolant heater power supply cord to the coolant heater.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .

1. Disconnect the engine coolant heater cord (1).
2. Remove the clips from the engine mount and surge tank.

1. Install the clips from the engine mount and surge tank.
2. Connect the engine coolant heater cord (1).

1. Disconnect the coolant heater power supply cord from the coolant heater (2).
2. Disconnect the coolant heater cord clip (1) from the engine.
3. Disconnect the coolant heater cord from between the washer bottle and the coolant reservoir (1).
4. Remove the coolant heater cord from the vehicle.

1. Connect the coolant heater cord to the coolant heater (2).
2. Secure the coolant heater cord clip (1) to the engine.
3. Route the coolant heater cord along the battery (2).
4. Secure the coiled power cord between the washer fluid bottle and the coolant reservoir (1).