Buick Encore: Engine Heating and Cooling - Repair instructions

Cooling system draining and filling

Draining Procedure

WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Remove the coolant pressure cap from the radiator surge tank.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front bumper opening lower cover. Refer to Front Bumper Fascia Opening Lower Cover Replacement (Encore) .
4. Place a drain pan under the drain cock.

Fig. 4: Radiator Drain Cock

5. Loosen the radiator drain cock (1).
6. Drain the cooling system.
7. Lower the vehicle.
8. Inspect the coolant.
9. Follow the appropriate procedure based on the condition of the coolant.

• Normal in appearance-Follow the filling procedure.
• Discolored-Follow the flush procedure. Refer to Coolant System Flushing.

Filling Procedure

CAUTION: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

1. Raise and support the vehicle.

Fig. 5: Radiator Drain Cock

CAUTION: Refer to Fastener Caution .

2. Tighten the radiator drain cock (1).
3. Install the front bumper opening lower cover. Refer to Front Bumper Fascia Opening Lower Cover Replacement (Encore) .
4. Lower the vehicle.

NOTE: Use a 50/50 mixture of DEX-COOL antifreeze and clean drinkable water.

5. Slowly fill the radiator with a 50/50 coolant mixture until the coolant level reaches the base of the radiator surge tank. Refer to Approximate Fluid Capacities .
6. Allow 30 seconds for the coolant level to stabilize and continue to fill the coolant filler neck until the level stabilizes for at least 2 minutes.
7. Start the engine and allow to the engine to idle in PARK or NEUTRAL with the parking brake engaged.
8. Slowly fill the coolant mixture until the level stabilizes at the base of the radiator surge tank.
9. Install the coolant pressure cap.
10. Raise the engine RPM to 2500 rpm for 30-40 seconds.
11. Shut the engine OFF.
12. Allow the engine to cool, remove coolant fill cap and repeat steps 4-10 until the coolant level has completely stabilized within the radiator surge tank.
13. Inspect and if necessary, fill the coolant reservoir bottle as necessary.
14. Rinse away any excess coolant from the engine and the engine compartment.
15. Inspect the cooling system for leaks.
16. Top off the radiator surge tank if necessary.

Coolant system flushing

NOTE:

• Do not use a chemical flush.
• Store used coolant in the proper manner, such as in a used engine coolant holding tank.
• Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical.
• Do not dispose of coolant into the sewer system or ground water. This is illegal and ecologically unsound.
• Various methods and equipment can be used to flush the cooling system.

  If special equipment is used, such as a back flusher, follow the manufactures instruction. However, always remove the thermostat before back flushing the system.

1. Apply the parking brake.
2. Drain the coolant. Refer to Cooling System Draining and Filling.
3. Fill the cooling system with clean drinkable water. Refer to Cooling System Draining and Filling.
4. Start the engine and run at 2,000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to Cooling System Draining and Filling.
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to Cooling System Draining and Filling.
9. Repeat the above procedure until the water from the coolant system is colorless. Refer to Cooling System Draining and Filling.

RADIATOR CLEANING

WARNING: NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury.

CAUTION: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer.

NOTE:

Blow compressed air through the engine side of the radiator to remove any foreign material, such as insects, leaves, and dust.

• Warm water and mild soap may be needed in some conditions.
• Wash the A/C condenser fin.
• Wash the A/C condenser and radiator thoroughly.
• Wash the radiator cooling fin.
• Repair any damaged cooling fin.

RADIATOR SURGE TANK REPLACEMENT (LUV, 2H0, LUJ)

Fig. 6: Radiator Surge Tank

Radiator Surge Tank Replacement (LUV, 2H0, LUJ)

RADIATOR SURGE TANK OUTLET HOSE REPLACEMENT (LUJ, LUV)

Fig. 7: Radiator Surge Tank Outlet Hose

Radiator Surge Tank Outlet Hose Replacement (LUJ, LUV)

RADIATOR SURGE TANK OUTLET HOSE REPLACEMENT (2H0)

Fig. 8: Radiator Surge Tank Outlet Hose

Radiator Surge Tank Outlet Hose Replacement (2H0)

RADIATOR INLET HOSE REPLACEMENT (LUJ, LUV)

Fig. 9: Radiator Inlet Hose (LUJ, LUV)

Radiator Inlet Hose Replacement (LUJ, LUV)

RADIATOR INLET HOSE REPLACEMENT (2H0)

Fig. 10: Radiator Inlet Hose (2H0)

Radiator Inlet Hose Replacement (2H0)

RADIATOR OUTLET HOSE REPLACEMENT (LUJ, LUV)

Fig. 11: Radiator Outlet Hose (LUJ, LUV)

Radiator Outlet Hose Replacement (LUJ, LUV)

RADIATOR OUTLET HOSE REPLACEMENT (2H0)

Fig. 12: Radiator Outlet Hose (2H0)

Radiator Outlet Hose Replacement (2H0)

RADIATOR OUTLET HOSE CONNECTOR REPLACEMENT - RADIATOR SIDE (LUJ, LUV)

Fig. 13: Radiator Outlet Hose Connector - Radiator Side (LUV)

Radiator Outlet Hose Connector Replacement - Radiator Side (LUJ, LUV)

RADIATOR OUTLET HOSE CONNECTOR REPLACEMENT - ENGINE SIDE (LUJ, LUV)

Fig. 14: Radiator Outlet Hose Connector - Engine Side (LUV)

Radiator Outlet Hose Connector Replacement - Engine Side (LUJ, LUV)

RADIATOR MOUNTING STUD REPAIR

Repair Procedure

NOTE:

If the radiator is leaky, replace it. Refer to Radiator Replacement (LUJ, LUV), Radiator Replacement (2HO, LDE).

1. Pressure test the cooling system. Refer to Cooling System Leak Testing.

Fig. 15: Identifying Fracture Surface

2. Grind the fracture surface (1) with a proper tool.
3. Drill a hole in the center of the fractured surface, using a 6 mm (0.24 in) drill.

Fig. 16: Radiator Mounting Pin, Nut And Bolt

4. Install the new radiator mounting pin (2).

• Install the nut (3).

NOTE: The bolt should not be longer than 35 mm (1.38 in).

• Install the radiator mounting pin (2) with the bolt (1).

CAUTION: Refer to Fastener Caution .

5. Tighten the bolt 5 N.m (44 lb in).

RADIATOR UPPER BRACKET REPLACEMENT (2H0)

Fig. 17: Radiator Upper Bracket (2H0)

Radiator Upper Bracket Replacement (2H0)

RADIATOR UPPER BRACKET REPLACEMENT (LUJ, LUV)

Fig. 18: Radiator Upper Bracket

Radiator Upper Bracket Replacement (LUJ, LUV)

THROTTLE BODY HEATER INLET HOSE REPLACEMENT (2H0)

Fig. 19: Throttle Body Heater Inlet Hose (2H0)

Throttle Body Heater Inlet Hose Replacement (2H0)

THROTTLE BODY HEATER INLET PIPE REPLACEMENT (2H0)

Fig. 20: Throttle Body Heater Inlet Pipe (2H0)

Throttle Body Heater Inlet Pipe Replacement (2H0)

THROTTLE BODY HEATER OUTLET PIPE REPLACEMENT (2H0)

Fig. 21: Throttle Body Heater Outlet Pipe (2H0)

Throttle Body Heater Outlet Pipe Replacement (2H0)

THROTTLE BODY HEATER OUTLET HOSE REPLACEMENT (2H0)

Fig. 22: Throttle Body Heater Outlet Hose (2H0)

Throttle Body Heater Outlet Hose Replacement (2H0)

ENGINE OIL COOLER COOLANT INLET HOSE REPLACEMENT (LUJ)

Fig. 23: Engine Oil Cooler Coolant Inlet Hose

Engine Oil Cooler Coolant Inlet Hose Replacement (LUJ)

ENGINE OIL COOLER PIPE REPLACEMENT (2H0, LDE)

Fig. 24: Engine Oil Cooler Pipe (SHO)

Engine Oil Cooler Pipe Replacement (2H0, LDE)

ENGINE OIL COOLER INLET PIPE REPLACEMENT (2H0, LDE)

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the exhaust manifold with catalytic converter.

Fig. 25: Identifying Engine Oil Cooler Outlet Pipe And Bolts

3. Remove the engine oil cooler pipe bolts (1) and the engine oil cooler pipe (2).

Fig. 26: Engine Oil Cooler Outlet Pipe Bracket And Bolts

4. Remove the engine oil cooler outlet pipe bolts (1) and the engine control module (ECM) harness bracket (2).

Fig. 27: Engine Oil Cooler Assembly Components

5. Remove the engine oil cooler assembly bolts (1) and remove the cooler (2).
6. Remove the engine oil cooler inlet pipe (4) and seals (3).

Installation Procedure

1. Replace the seals on the engine oil cooler outlet pipe and the engine oil cooler pipe.

Fig. 28: Engine Oil Cooler Assembly Components

2. Install the engine oil cooler inlet pipe (4) with NEW seals (3) to the engine oil cooler assembly.
3. Position the engine oil cooler assembly (2) to the engine block.

CAUTION: Refer to Fastener Caution .

4. Install the engine oil cooler assembly bolts (1) and tighten to 25 N.m (19 lb ft).

Fig. 29: Engine Oil Cooler Outlet Pipe Bracket And Bolts

5. Install the engine oil cooler outlet pipe mounting bolts (1) and ECM bracket (2) to the water pump housing and tighten to 8 N.m (71 lb in).

Fig. 30: Identifying Engine Oil Cooler Outlet Pipe And Bolts

6. Install the engine oil cooler pipe (2) to the thermostat housing and tighten bolts (1) to 8 N.m (71 lb in).
7. Install the exhaust manifold with catalytic converter.
8. Fill the cooling system. Refer to Cooling System Draining and Filling.
9. Start the engine and check for coolant leaks.

ENGINE OIL COOLER INLET PIPE REPLACEMENT (LUJ)

Fig. 31: Engine Oil Cooler Inlet Pipe (LUJ)

Engine Oil Cooler Inlet Pipe Replacement (LUJ)

ENGINE COOLANT FAN REPLACEMENT (LUJ, LUV)

Fig. 32: Engine Coolant Fan

Engine Coolant Fan Replacement (LUJ, LUV)

ENGINE COOLANT FAN REPLACEMENT (2H0)

Fig. 33: Engine Coolant Fan (2H0)

Engine Coolant Fan Replacement (2H0)

TURBOCHARGER COOLANT FEED PIPE REPLACEMENT (LUJ)

Special Tools

EN-49940 Remover Quick Connector

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the turbocharger. Refer to Turbocharger Replacement

Fig. 34: Turbocharger Coolant Feed Pipe

NOTE: The quick fitting connectors should be always replaced when the turbocharger coolant pipes are removed.

2. Install the EN-49940 remover (2) to the turbocharger coolant feed pipe (1) and the quick fitting connector as shown.
3. Compress the EN-49940 remover and remove the turbocharger coolant feed pipe direction of the arrow.

Fig. 35: Quick Fitting Connector And Seal Ring

4. Remove the quick fitting connector (2) and the seal ring (1).

Installation Procedure

Fig. 36: Quick Fitting Connector And Seal Ring

CAUTION: Refer to Fastener Caution

1. Install the NEW quick fitting connector (2) and a NEW quick fitting connector seal ring (1) to the turbocharger and tighten to 20 N.m (15 lb ft).

Fig. 37: Turbocharger Coolant Feed Pipe

2. Install the turbocharger coolant feed pipe (1) to the quick fitting connector (2) by pushing in direction of the arrow until it engages audible.
3. Install the turbocharger. Refer to Turbocharger Replacement .

Turbocharger coolant return pipe replacement (LUJ)

Special Tools

EN-49940 Quick Connector Remover

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the turbocharger. Refer to Turbocharger Replacement

Fig. 38: Turbocharger Coolant Return Pipe

2. Install the EN-49940 Quick Connector Remover (2) to the turbocharger coolant return pipe (1) and the quick fitting connector as shown.
3. Compress the EN-49940 Quick Connector Remover and remove the turbocharger coolant return pipe in direction of the arrow.

Fig. 39: Turbocharger Coolant Return Pipe And Quick Connect Fitting

4. Remove the turbocharger coolant return pipe (1) from the quick connect fitting (2).

Fig. 40: Quick Fitting Connector Seal Ring

5. Remove the quick fitting connector (2) and the quick fitting connector seal ring (1).

Installation Procedure

Fig. 41: Quick Fitting Connector Seal Ring

CAUTION: Refer to Fastener Caution .

1. Install the NEW quick fitting connector (2) and a NEW quick fitting connector seal ring (1) to the turbocharger and tighten to 20 N.m (15 lb ft).

Fig. 42: Turbocharger Coolant Return Pipe And Quick Connect Fitting

2. Install the turbocharger coolant return pipe (1) to the quick fitting connector (2) by pushing in direction of the arrow until it engages audible.
3. Install the turbocharger. Refer to Turbocharger Replacement .

Engine coolant thermostat housing replacement (2H0, LDE)

Removal Procedure

CAUTION: Refer to Engine Coolant Thermostat Housing Caution

1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Drain the cooling system. Refer to Cooling System Draining and Filling.

Fig. 43: Engine Wiring Harness Connector And Retainers

4. Disconnect the engine harness connector (1) and harness fasteners (2) from the engine harness bracket, attached to the thermostat housing.

Fig. 44: Wiring Harness Bracket And Nut

5. Disconnect the throttle body heater inlet hose (1) and the electrical connectors (2) to the thermostat housing.
6. Remove the engine harness bracket nut (3) and bracket (4) from the thermostat housing.

Fig. 45: Thermostat Heating Element Sensor & Radiator Inlet Hose

7. Remove the radiator inlet hose (2) to the engine coolant thermostat housing.
8. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement (2H0) .
9. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement (2H0) .

Fig. 46: Identifying Engine Oil Cooler Outlet Pipe And Bolts

10. Remove the engine oil cooler outlet pipe bolts (1).
11. Remove the engine oil cooler outlet pipe (2) from the engine coolant thermostat housing.

Fig. 47: Engine Coolant Thermostat Housing, Seal And Mounting Bolts

12. Remove the engine coolant thermostat housing mounting bolts (1) and discard the seal (2).
13. Remove the engine coolant thermostat housing (3) from the engine.

Installation Procedure

1. Clean the sealing surface.

Fig. 48: Engine Coolant Thermostat Housing, Seal And Mounting Bolts

2. Install a NEW engine coolant thermostat housing seal (2).
3. Loosely install the engine coolant thermostat housing mounting bolts (1).

Fig. 49: Identifying Engine Coolant Thermostat Housing Bolts Tightening Sequence

CAUTION: Following the proper fastener tightening sequence and torque is essential. Failure to do so may fracture the thermostat housing.

CAUTION: Refer to Fastener Caution

4. Tighten the 4 engine coolant thermostat housing bolts to 8 N.m (71 lb in) in sequence (1-2-3-4).

Fig. 50: Identifying Engine Coolant Temperature Sensor Connector, Engine Oil Cooler Pipe And Thermostat Housing

5. Install NEW engine oil cooler pipe seals (4, 7).

NOTE: Push the engine oil cooler pipe into the engine oil cooler.

6. Install the engine oil cooler pipe (5).
7. Install the 2 engine oil cooler pipe bolts (6) and tighten to 8 N.m (71 lb in).
8. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement (2H0) .
9. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement (2H0) .

Fig. 51: Wiring Harness Bracket And Nut

10. Connect the electrical connectors (2) to the engine coolant thermostat housing.
11. Install the throttle body heater inlet hose (1) to the engine coolant thermostat housing.
12. Install the engine coolant thermostat housing bracket (4) and nut (3) and tighten to 6 N.m (53 lb in).

Fig. 52: Thermostat Heating Element Sensor & Radiator Inlet Hose

13. Install the radiator inlet hose (2) to the engine coolant thermostat housing.
14. Fill the cooling system. Refer to Cooling System Draining and Filling.
15. Install the battery tray. Refer to Battery Tray Replacement .
16. Start the engine and check for coolant leaks.

Engine coolant thermostat replacement  (2H0, LDE, LFH)

Removal Procedure

WARNING: Refer to Battery Disconnect Warning .

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Drain the coolant. Refer to Cooling System Draining and Filling.

Fig. 53: Engine Wiring Harness Connector And Retainers

3. Disconnect the engine wiring harness connector (1) and retainers (2).

Fig. 54: Wiring Harness Bracket And Nut

4. Remove the wiring harness bracket nut (3) and bracket (4).

Fig. 55: Thermostat Heating Element Sensor & Radiator Inlet Hose

5. If equipped, disconnect the thermostat heating element sensor (1) and remove the radiator inlet hose (2).

Fig. 56: Thermostat Housing And Retaining Bolts

6. Remove the thermostat housing retaining bolts (1).

Fig. 57: Thermostat And Discard Seal

7. Remove the thermostat (1) and discard the seal (2).

Installation Procedure

Fig. 58: Thermostat And Discard Seal

1. Fit the thermostat (1) to the thermostat housing using a NEW seal (2).

Fig. 59: Thermostat Housing And Retaining Bolts

CAUTION: Refer to Fastener Caution .

2. Install the thermostat (2) and tighten the thermostat bolts (1) to 10 N.m (89 lb in).

Fig. 60: Thermostat Heating Element Sensor & Radiator Inlet Hose

3. Install the radiator inlet hose (2) and connect the thermostat heating element sensor (1).

Fig. 61: Wiring Harness Bracket And Nut

4. Install the wiring harness bracket (4) and tighten the nut (3) to 10 N.m (89 lb in).

Fig. 62: Engine Wiring Harness Connector And Retainers

5. Connect the engine harness connector (1) and harness retainers (2) to the bracket.
6. Refill the engine cooling system. Refer to Cooling System Draining and Filling.
7. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
8. Start the engine and check for coolant leaks.

Engine coolant thermostat replacement (LUV, LUJ)

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

Fig. 63: Engine Coolant Temperature Sensor Connector And Radiator Outlet Hose

3. Remove the engine coolant temperature sensor connector (1).
4. Disconnect the radiator outlet hose connector (2) from the engine coolant thermostat and reposition. Refer to Radiator Outlet Hose Connector Replacement - Engine Side (LUJ, LUV).

Fig. 64: Thermostat, Water Inlet Pipe & Components

5. Remove the water inlet pipe mounting fasteners (1).
6. Remove the water inlet seal (3) and discard.
7. Remove the thermostat (4).

Installation Procedure

1. Clean the sealing surface.

Fig. 65: Thermostat, Water Inlet Pipe & Components

2. Install the engine thermostat (4) into the water inlet pipe (2) with a NEW seal (3).
3. Tighten the water inlet pipe mounting fasteners (1) to 9 N.m (80 lb in).

Fig. 66: Engine Coolant Temperature Sensor Connector And Radiator Outlet Hose

4. Install the radiator outlet hose connector (2) to the engine coolant thermostat. Refer to Radiator Outlet Hose Connector Replacement - Engine Side (LUJ, LUV).
5. Connect the engine coolant temperature sensor connector (1).
6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
7. Fill the cooling system. Refer to Cooling System Draining and Filling.
8. After repairs, inspect cooling system for leaks.

ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (2H0)

Fig. 67: Engine Coolant Air Bleed Hose (2HO)

Engine Coolant Air Bleed Hose Replacement (2H0)

ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (LUJ, LUV)

Fig. 68: Engine Coolant Air Bleed Hose (LUV)

Engine Coolant Air Bleed Hose Replacement (LUJ, LUV)

Water outlet replacement (LUJ, LUV)

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement .
3. Remove the engine coolant air bleed hose from the water outlet. Refer to Engine Coolant Air Bleed Hose Replacement (LUJ, LUV).
4. Remove the heater inlet hose from the water outlet. Refer to Heater Inlet Hose Replacement (LUJ, LUV) .
5. Remove the radiator inlet hose from the water outlet. Refer to Radiator Inlet Hose Replacement (LUJ, LUV).
6. Remove the engine oil cooler coolant inlet hose from the water outlet. Refer to Engine Oil Cooler Coolant Inlet Hose Replacement (LUJ).
7. Disconnect the engine coolant temperature sensor (water outlet) wiring harness connector.

Fig. 69: Water Outlet

8. Remove the 3 water outlet bolts (3).
9. Remove the water outlet (2) and the water outlet seal ring (1).

Installation Procedure

1. Clean the sealing surfaces.

Fig. 70: Water Outlet

2. Install the water outlet (2) and a NEW water outlet seal ring (1).

CAUTION: Refer to Fastener Caution .

3. Install the 3 water outlet bolts (3) and tighten to 8 N.m (71 lb in).
4. Connect the engine coolant temperature sensor (water outlet) wiring harness connector.
5. Install the engine oil cooler coolant inlet hose to the water outlet. Refer to Engine Oil Cooler Coolant Inlet Hose Replacement (LUJ).
6. Install the radiator inlet hose to the water outlet. Refer to Radiator Inlet Hose Replacement (LUJ, LUV).
7. Install the heater inlet hose to the water outlet. Refer to Heater Inlet Hose Replacement (LUJ, LUV) .
8. Install the engine coolant air bleed hose to the water outlet. Refer to Engine Coolant Air Bleed Hose Replacement (LUJ, LUV).
9. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement .
10. Fill the cooling system. Refer to Cooling System Draining and Filling.

WATER PUMP PULLEY REPLACEMENT (2H0, LDE)

Removal Procedure

1. Remove the engine from the vehicle. Refer to Engine Replacement (Automatic Transmission), Engine Replacement (Manual Transmission).

Fig. 71: Water Pump And Water Pump Pulley

NOTE: Counterhold against crankshaft balancer bolt.

2. Loosen the 3 water pump pulley bolts (1).
3. Remove the drive belt. Refer to Drive Belt Replacement.
4. Remove the 3 water pump pulley bolts (1).
5. Remove the water pump pulley (2) from the water pump (3).

Installation Procedure

Fig. 72: Water Pump And Water Pump Pulley

1. Install the water pump pulley (2) to the water pump (3).
2. Install the 3 water pump pulley bolts (1).
3. Install the drive belt. Refer to Drive Belt Replacement.

CAUTION: Refer to Fastener Caution .

NOTE: Counterhold against crankshaft balancer bolt.

4. Tighten the 3 water pump pulley bolts (1) to 20 N.m (15 lb ft).
5. Install the engine into the vehicle. Refer to Engine Replacement (Automatic Transmission), Engine Replacement (Manual Transmission).

WATER PUMP PULLEY REPLACEMENT (LUJ, LUV)

Fig. 73: Water Pump Pulley

Water Pump Pulley Replacement (LUJ, LUV)

WATER PUMP REPLACEMENT (2H0)

Fig. 74: Water Pump (2HO)

Water Pump Replacement (2H0)

WATER PUMP REPLACEMENT (LUJ, LUV)

Special Tools

EN-45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the engine coolant thermostat from water pump. Refer to Engine Coolant Thermostat Replacement (LUV, LUJ).
3. Remove the water pump pulley. Refer to Water Pump Pulley Replacement (LUJ, LUV)
4. Remove the heater outlet hose from the water pump. Refer to Heater Outlet Hose Replacement (LUJ, LUV) , Heater Outlet Hose Replacement (LUJ, LUV Rear) .

Fig. 75: Water Pump, Bolts And Gasket

5. Remove the 5 water pump bolts (4) and the 5 long engine front cover bolts (3).
6. Remove the water pump (2).
7. Remove and DISCARD the water pump gasket (1).

Installation Procedure

1. Clean the sealing surfaces.

Fig. 76: Water Pump And Engine Front Cover Bolts

2. The water pump and engine front cover bolts are located as followed:

• Engine front cover special bolt without cone end 60 mm (2.362 in) (1).
• Engine front cover standard bolt with cone end 52 mm (2.047 in) (2).
• Water pump bolt 25 mm (0.984 in) (3).

Fig. 77: Water Pump, Bolts And Gasket

3. Install the water pump (2) and a NEW water pump gasket (1).

CAUTION: Refer to Fastener Caution .

4. Install the 5 water pump bolts (4) and the 5 engine front cover bolts (3) and tighten in a cross sequence to 8 (71 lb in).

Fig. 78: Identifying Water Pump Bolts

CAUTION: Refer to Torque-to-Yield Fastener Caution

5. Tighten the 2 water pump bolts (1) to an additional 30 degrees, using the EN-45059 meter.
6. Install the heater outlet hose from the water pump. Refer to Heater Outlet Hose Replacement (LUJ, LUV) , Heater Outlet Hose Replacement (LUJ, LUV Rear) .
7. Install the water pump pulley. Refer to Water Pump Pulley Replacement (LUJ, LUV).
8. Install the engine coolant thermostat to the water pump. Refer to Engine Coolant Thermostat Replacement (LUV, LUJ).
9. Fill the cooling system. Refer to Cooling System Draining and Filling.

ENGINE COOLANT FAN SHROUD REPLACEMENT (2H0)

Fig. 79: Engine Coolant Fan Shroud

Engine Coolant Fan Shroud Replacement (2H0)

ENGINE COOLANT FAN SHROUD REPLACEMENT (LUJ, LUV)

Fig. 80: Engine Coolant Fan Shroud (LUJ, LUV)

Engine Coolant Fan Shroud Replacement (LUJ, LUV)

Radiator replacement  (LUJ, LUV)

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Encore) , Front Bumper Fascia Replacement (Encore) .
3. Drain the coolant fluid. Refer to Cooling System Draining and Filling.
4. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging (R-134a) .
5. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LUJ, LUV).
6. Remove the radiator inlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LUJ, LUV).
7. Remove the center support bracket. Refer to Front Bumper Fascia Center Support Replacement .
8. Remove the front bumper lower impact bar. Refer to Front Bumper Lower Impact Bar Replacement (Encore) .
9. Remove the radiator air upper baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (LUJ, LUV).
10. Remove the radiator air lower baffle and deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement (LUJ, LUV).
11. Remove the charge air cooler. Refer to Charge Air Cooler Replacement .
12. Remove the condenser. Refer to Air Conditioning Condenser Replacement (LUV) .

Fig. 81: Coolant Fan Wiring Harness Connector

13. Disconnect the coolant fan wiring harness connector (1).
14. Remove the temperature sensor from the radiator. Refer to Engine Coolant Temperature Sensor Replacement (Water Outlet) , Engine Coolant Temperature Sensor Replacement (Radiator) .
15. Remove both radiator upper brackets. Refer to Radiator Upper Bracket Replacement (LUJ, LUV).

Fig. 82: Radiator

16. Remove the radiator (1) downward, and place the radiator on the table.

Fig. 83: Engine Cooling Fan

17. Remove the engine cooling fan retaining bolts (1).
18. Remove the engine cooling fan (2) from the radiator (3).

Installation Procedure

Fig. 84: Engine Cooling Fan

1. Position the engine cooling fan (2) to the radiator (3).

CAUTION: Refer to Fastener Caution

2. Install the engine cooling fan retaining bolts (1) and tighten to 10 (89 lb in).

Fig. 85: Radiator

3. Reposition the radiator, and install both radiator upper brackets. Refer to Radiator Upper Bracket Replacement (LUJ, LUV).
4. Install the temperature sensor to the radiator. Refer to Engine Coolant Temperature Sensor Replacement (Water Outlet) , Engine Coolant Temperature Sensor Replacement (Radiator) .

Fig. 86: Coolant Fan Wiring Harness Connector

5. Connect the coolant fan wiring harness connector (1).
6. Install the condenser. Refer to Air Conditioning Condenser Replacement (LUV) .
7. Install the charge air cooler. Refer to Charge Air Cooler Replacement .
8. Install the radiator air lower baffle and deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement (LUJ, LUV).
9. Install the radiator air upper baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (LUJ, LUV).
10.  Install the front bumper lower impact bar. Refer to Front Bumper Lower Impact Bar Replacement (Encore) .
11. Install the center support bracket. Refer to Front Bumper Fascia Center Support Replacement .
12. Install the radiator inlet hose to the radiator. Refer to Radiator Outlet Hose Replacement (LUJ, LUV).
13. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement (LUJ, LUV).
14. Fill the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging (R-134a) .
15. Fill the coolant fluid. Refer to Cooling System Draining and Filling.
16. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Encore) , Front Bumper Fascia Replacement (Encore) .
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection

RADIATOR REPLACEMENT (2HO, LDE)

Fig. 87: Radiator (2H0)

Radiator Replacement (2HO, LDE)

RADIATOR SUPPORT BAFFLE REPLACEMENT

Fig. 88: Radiator Support Baffle

Radiator Support Baffle Replacement

RADIATOR AIR LOWER BAFFLE AND DEFLECTOR REPLACEMENT (2H0)

Fig. 89: Radiator Air Lower Baffle and Replacement (2H0)

Radiator Air Lower Baffle and Deflector Replacement (2H0)

RADIATOR AIR LOWER BAFFLE AND DEFLECTOR REPLACEMENT (LUJ, LUV)

Fig. 90: Radiator Air Lower Baffle and Deflector (LUJ, LUV)

Radiator Air Lower Baffle and Deflector Replacement (LUJ, LUV)

RADIATOR AIR UPPER BAFFLE AND DEFLECTOR REPLACEMENT (LUJ, LUV)

Fig. 91: Radiator Air Upper Baffle and Deflector (LUJ, LUV)

Radiator Air Upper Baffle and Deflector Replacement (LUJ, LUV)

RADIATOR AIR UPPER BAFFLE AND DEFLECTOR REPLACEMENT (2H0)

Fig. 92: Radiator Air Upper Baffle and Deflector (2H0)

Radiator Air Upper Baffle and Deflector Replacement (2H0)

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