2000 01 engine cooling

2000-01 ENGINE COOLING

Removal & Installation - L Series (V6)

BLEEDING

COOLING SYSTEM

1. Slowly add a mixture of 50/50 DEX-COOL(R) antifreeze and clean water to coolant surge tank until the level reaches the "Cold" line (surge tank seam). See Fig. 1 .

2. Cooling system volumes, including heater core are 7.4 L (7.8 qt.).

3. Start engine and check for leaks.

4. Run engine until thermostat has opened.

5. Use Tech 2, or equivalent scan tool, to verify coolant temperature is between 87°- 90° C (188° -196° F).

6. Cycle RPM from idle to 3000 in 30 seconds intervals to aid bleeding of cooling system.

7. Add coolant as necessary to bring level up to coolant surge tank "Cold" line (surge tank seam).

8. Install coolant surge tank coolant cap.

NOTE: Vehicle must be level when filling cooling sys tem.

2001 Saturn L300

2000-01 ENGINE COOLING Removal & Installation - L Series (V6)

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Monday, May 09, 2011 11:34:46 AM Page 1 © 2006 Mitchell Repair Information Company, LLC.

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Fig. 1: Locating Cooling System Components & Flow Diagram Courtesy of GENERAL MOTORS CORP.

REMOVAL & INSTALLATION

AUXILIARY WATER PUMP

NOTE: The auxiliary water pump is located on the rig ht rear side of the puller fan

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Removal

1. Remove puller fan and shroud.

2. Remove auxiliary water pump inlet hose to auxiliary water pump inlet clamp and remove hose. See Fig. 2 .

3. Remove auxiliary water pump outlet hose to auxiliary water pump outlet clamp and remove hose.

4. Remove auxiliary water pump to fan shroud clip by lifting clip tab with a screwdriver and sliding clips outward. See Fig. 3 .

shroud. The pump is rubber mounted to the shroud. T he propose of the auxiliary water pump is to prevent coolant boil ove r after engine shutdown by cycling coolant through the radiator when the engin e is turned OFF. Under high ambient conditions, at ignition OFF, the pusher and puller fans will run is series (6 volts each) along with the auxiliary water pump for several minutes. The auxiliary pump does not run at any other time. The auxiliary water pump and mounting bracket are serviced as an assembly.

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Fig. 2: Installing Auxiliary Water Pump Inlet & Outlet Hoses Courtesy of GENERAL MOTORS CORP.

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Fig. 3: Installing Auxiliary Water Pump To Fan Shroud Clips Courtesy of GENERAL MOTORS CORP.

Installation

1. Install auxiliary water pump fan shroud clips. See Fig. 3 .

2. Install auxiliary water pump inlet hose to auxiliary water pump inlet and install clamp at 12 o'clock position. See Fig. 2 .

3. Install auxiliary water pump outlet hose to auxiliary water pump outlet and install clamp so tangs face rear of vehicle.

4. Install puller fan and shroud assembly.

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5. Use fresh water to rinse away coolant that was spilled during service.

6. Fill and bleed air from cooling system. See BLEEDING .

HEATER INLET/OUTLET & HEATER WATER PUMP

Fig. 4: Identifying Auxiliary Heater Water Pump Courtesy of GENERAL MOTORS CORP.

Removal

1. Disconnect negative battery cable. See Fig. 5 .

2. Drain coolant.

3. Position approved coolant container under vehicle below heater hose connections to catch any coolant that may be trapped in heater hoses.

4. Open heater hose assembly to manifold clamp. See Fig. 6 .

NOTE: The heater water pump is located on the back s ide of the engine. The pump is rubber mounted to the engine block and is in series with the heater core inlet hose. The purpose of the is to increase the flow of engine coolant through the heater core. This water pump runs whenever the igni tion is turned ON. The heater water pump and mounting bracket are serviced as an assembly. See Fig. 4 .

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Fig. 5: Disconnecting Negative Battery Cable Courtesy of GENERAL MOTORS CORP.

NOTE: Green plastic rings may be found hanging on th e pipes after hose removal; these are manufacturing aids and should be discarded.

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Fig. 6: Removing Heater Hose To Manifold Clamp Courtesy of GENERAL MOTORS CORP.

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Fig. 7: Removing Heater Core Inlet Hose Quick Connect Collar Tab Courtesy of GENERAL MOTORS CORP.

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Fig. 8: Removing Inlet Hose From Heater Core Courtesy of GENERAL MOTORS CORP.

5. Remove heater core inlet hose from heater core pipe by depressing quick connect collar tab, located at 6 o'clock, and pulling black collar towards front of vehicle and then pulling quick connect off heater core pipe. See Fig. 7 and Fig. 8 .

6. Remove heater core outlet hose from heater core pipe by depressing quick connect collar tab, located at 6 o'clock, and pulling white collar towards front of vehicle and then pulling quick connect off heater core pipe. See Fig. 9 .

7. Remove return hose to engine housing clamp and remove return hose. See Fig. 10 .

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Fig. 9: Removing Outlet Hose From Heater Core Courtesy of GENERAL MOTORS CORP.

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Fig. 10: Removing Heater Outlet Hose From Engine Inlet Courtesy of GENERAL MOTORS CORP.

8. Remove heater core outlet hose to engine coolant inlet housing clamp and remove hose.

9. Remove heater inlet hose to coolant bridge clamp and remove hose. See Fig. 11 .

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Fig. 11: Removing Heater Inlet Hose to Coolant Bridge Courtesy of GENERAL MOTORS CORP.

10. Disconnect electrical connector from heater water pump. See Fig. 12 .

11. Remove heater water pump mount and heat shield to bracket bolt and remove mount and heat shield. See Fig. 13 .

12. Remove inlet and outlet hose to heater water pump clamps and remove hoses. See Fig. 14 .

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Fig. 12: Removing Electrical Connector From Auxiliary Heater Water Pump Courtesy of GENERAL MOTORS CORP.

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Fig. 13: Removing Auxiliary Heater Water Pump Courtesy of GENERAL MOTORS CORP.

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Fig. 14: Removing Inlet & Outlet Hose From Auxiliary Heater Water Pump Courtesy of GENERAL MOTORS CORP.

Installation

1. Install block bolt to heater water pump mount and heat shield. See Fig. 13 .

2. Install heater water pump electrical connector. See Fig. 12 .

3. Install heater inlet hose to coolant bridge and install clamp at 12 o'clock position. See Fig. 11 .

4. Install heater inlet hose to heater pump and install clamp at 1 o'clock position.

5. Install heater pipe heater inlet hose to heater pump and install clamp at 12 o'clock position. See Fig. 14 .

6. Install heater outlet hose to engine coolant inlet and install clamp. See Fig. 10 .

7. Install return line to coolant bridge and install clamp at 2 o'clock position.

8. Install heater core inlet quick connect to heater inlet pipe (closest to driver's side). Holding quick connect by black collar, slide onto heater core pipe. When quick connect engages heater core pipe bead, collar will slide towards front of dash and lock into position. A green paint band will be visible when collar is properly positioned. See Fig. 7 .

9. Verify proper engagement of quick connect by attempting to pull off of heater pipe.

NOTE: Heater inlet hose quick connect coupling colla r is black. The heater outlet hose quick connect coupling is white. White lines on hos es should always be installed at 12 o'clock position. Install heater ho se/heater water pump assembly into manifold clamp but do not lock clamp.

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10. Install heater core outlet quick connect to heater outlet pipe (closest to passenger's side). Holding quick connect by white collar, slide onto heater core pipe. When quick connect engages heater core pipe bead, collar will slide towards front of dash and lock into position. A green paint band will be visible when collar is properly positioned.

11. Verify proper engagement of quick connect by attempting to pull off of heater pipe.

12. With hoses properly positioned, close heater assembly to manifold clamp.

13. Connect negative battery cable.

14. Fill and bleed air from cooling system. See BLEEDING .

15. Use fresh water to rinse away any coolant that was spilled during service.

RADIATOR

Removal

1. Disconnect negative battery cable.

2. Disconnect positive battery cable.

3. Remove fan control module by sliding up and off bracket. Lay module and wiring out of the way.

4. Remove battery insulating cover. See Fig. 15 .

5. Remove battery hold down fan control module bracket.

6. Remove battery.

7. Drain coolant.

8. Remove power steering fluid reservoir to fan shroud bolts and position reservoir rearward in car. See Fig. 16 .

NOTE: Make sure vehicle is properly supported and sq uarely positioned. To help avoid personal injury when a vehicle is on a hoist, provi de additional support for the vehicle on the opposite end from which components a re being removed.

NOTE: It is not necessary to disconnect fan control module wiring from module.

CAUTION: Do not tip battery over a 45 degree angle o r acid could spill.

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Fig. 15: Battery Insulator Cover Removal Courtesy of GENERAL MOTORS CORP.

Fig. 16: Removing Power Steering Fluid Reservoir Bolts Courtesy of GENERAL MOTORS CORP.

9. Disconnect both cooling fan electrical connectors. See Fig. 17 .

10. Remove electrical connectors from connector retainer by sliding connector as shown.

11. Remove pusher fan electrical harness from fan shroud retainer tabs.

12. Disconnect the auxiliary water pump electrical connector and remove harness from clip. See Fig. 18 .

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Fig. 17: Removing Cooling Fan Electrical Connectors Courtesy of GENERAL MOTORS CORP.

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Fig. 18: Disconnecting Auxiliary Water Pump Electrical Harness Courtesy of GENERAL MOTORS CORP.

13. Remove upper transaxle cooler line from radiator end tank and unsnap front end tank retainer. See Fig. 19 .

14. Cap or tape off transaxle oil cooler line to prevent oil loss or contamination.

15. Remove auxiliary water pump outlet hose to radiator end tank and remove hose. See Fig. 20 .

16. Remove upper radiator hose to radiator clamp and remove hose from radiator end tank. See Fig. 21 .

17. Raise vehicle.

18. Remove auxiliary water pump inlet hose to radiator end tank clamp and remove hose. See Fig. 22 .

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Fig. 19: Removing Upper Transaxle Cooler Line Courtesy of GENERAL MOTORS CORP.

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Fig. 20: Removing Auxiliary Water Pump Outlet Hose From Radiator Courtesy of GENERAL MOTORS CORP.

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Fig. 21: Removing Upper Radiator Hose From Radiator Courtesy of GENERAL MOTORS CORP.

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Fig. 22: Removing Auxiliary Water Pump Inlet Hose From Radiator Courtesy of GENERAL MOTORS CORP.

19. Lower vehicle.

20. Remove fan shroud to radiator bolts and remove shroud. See Fig. 23 .

21. Remove forward wiring harness from retaining clips (6). See Fig. 24 .

22. Remove lower radiator hose to radiator clamp and remove hose. See Fig. 25 .

23. Remove lower transaxle cooler line from radiator end tank. See Fig. 26 .

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Fig. 23: Removing Fan Shroud to Radiator Bolts Courtesy of GENERAL MOTORS CORP.

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Fig. 24: Removing Forward Wiring Harness From Retaining Clips Courtesy of GENERAL MOTORS CORP.

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Fig. 25: Removing Lower Radiator Hose From Radiator Courtesy of GENERAL MOTORS CORP.

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Fig. 26: Removing Lower Transaxle Cooler Line From Radiator

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Courtesy of GENERAL MOTORS CORP.

24. Cap or tape line and end tank to prevent oil spillage or contamination.

25. Remove radiator upper mount bracket to rail bolts and remove upper bracket and rubber mounts. See Fig. 27 .

26. Remove radiator degas hose to radiator clamp and remove degas hose, See Fig. 28 .

Fig. 27: Removing Radiator Upper Brackets & Rubber Mounts Courtesy of GENERAL MOTORS CORP.

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Fig. 28: Removing Radiator Degas Hose Courtesy of GENERAL MOTORS CORP.

27. Using a piece of wire or plastic tie, support condenser from upper rail.

28. Raise vehicle.

29. Remove condenser block to radiator end tank bolt. See Fig. 29 .

30. Remove condenser to radiator bolts. See Fig. 30 .

31. Pull condenser and pusher fan assembly down slightly to disengage tabs from radiator.

32. Lower vehicle.

NOTE: Do not open up the A/C system.

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33. Leaving condenser and pusher fan in vehicle, remove radiator from vehicle.

34. Remove upper and lower radiator to condenser gasket. See Fig. 31 .

Fig. 29: Removing Condenser Block to Radiator End Tank Bolt Courtesy of GENERAL MOTORS CORP.

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Fig. 30: Removing Condenser Fan to Radiator Bolts Courtesy of GENERAL MOTORS CORP.

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Fig. 31: Removing Upper & Lower Condenser Gaskets Courtesy of GENERAL MOTORS CORP.

Installation

1. Install upper radiator to condenser gasket on radiator. See Fig. 31 .

2. Install radiator lower mounting pins into rubber mounts. See Fig. 32 .

NOTE: White lines on hoses should be installed at th e 12 o'clock position.

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Fig. 32: Installing Lower Radiator Mounting Pins Into Rubber Mounts Courtesy of GENERAL MOTORS CORP.

3. Install radiator degas hose to radiator end tank and position clamp at 1 o'clock. See Fig. 28 .

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4. Position upper radiator mounts over upper pins and install radiator bracket to rail bolts. See Fig. 27 .

5. Raise vehicle.

6. Position condenser tabs under radiator tabs and install condenser to radiator bolts. See Fig. 33 .

Fig. 33: Installing Condenser To Radiator Tabs Courtesy of GENERAL MOTORS CORP.

7. Install lower radiator to condenser gasket. See Fig. 31 .

8. Install condenser block to radiator end tank bolt. See Fig. 29 .

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9. Lower vehicle.

10. Remove condenser support wire or plastic tie.

11. Remove cap and install lower transaxle cooler line to radiator end tank. See Fig. 26 .

12. Install lower radiator hose to radiator fitting. See Fig. 25 .

13. Install clamp at 11 o'clock position.

14. Install forward wiring harness into forward rail clips. See Fig. 24 .

15. Install fan and shroud assembly onto radiator lower tabs. See Fig. 34 .

Fig. 34: Installing Cooling Fan & Shroud Assembly Into Lower Radiator Tabs Courtesy of GENERAL MOTORS CORP.

16. Install fan shroud to radiator bolts. See Fig. 23 .

17. Raise vehicle.

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18. Install auxiliary water pump inlet hose to radiator end tank install clamp so tangs face outward. See Fig. 22 .

19. Raise vehicle.

20. Route auxiliary water pump outlet hose under fan shroud tab then install to radiator end tank and install clamp at the 12 o'clock position. See Fig. 20 .

21. Install upper transaxle oil cooler line into radiator end tank retainer. See Fig. 19 .

22. Remove cap and install upper transaxle oil cooler line to radiator end tank.

23. Connect circulation water pump electrical connector and install harness into clip. See Fig. 18 .

24. Route pusher fan electrical harness around outside of radiator end tank upper fan shroud.

25. Install fan electrical connectors into connector retainers as shown. See Fig. 17 .

26. Connect both fan electrical connectors.

27. Install pusher fan harness under routing tabs on fan shroud.

28. Install upper radiator hose to radiator end tank and position clamp at the 12 o'clock position. See Fig. 21 .

29. Install power steering fluid reservoir to fan shroud bolts. See Fig. 16 .

30. Verify battery tray is clean.

31. Install battery. See Fig. 35 .

32. Install battery hold down/fan control module bracket.

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Fig. 35: Installing Vehicle Battery Courtesy of GENERAL MOTORS CORP.

THERMOSTAT

Removal

1. Drain coolant.

2. Remove intake plenum. See Fig. 36 . For more information on removing intake pleum, see 3.0L DOHC V6 SATURN "L" SERIES article in ENGINE.

NOTE: During extremely cold weather, 10° F (-12° C) or colder, your engine's coolant temperature will decrease quickly when idling with the heater fan on high speed and cool air may flow from the heater outlets. The fan control switch can be set at a slower speed position (fan speed I or II) to m aintain the hottest air flow.

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Fig. 36: Removing Intake Manifold Courtesy of GENERAL MOTORS CORP.

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3. Remove intake manifold.

4. Remove radiator hose from inlet housing.

Fig. 37: Removing Thermostat Extension Housing Bolt Courtesy of GENERAL MOTORS CORP.

NOTE: It may be necessary to lift engine with floor jack to allow extension housing to be removed over radiator.

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Fig. 38: Removing Thermostat Housing Courtesy of GENERAL MOTORS CORP.

5. Remove thermostat extension housing bolt and extension housing. See Fig. 37 .

6. Remove and discard O-ring seals.

7. Remove bolts. Tilt the rear of the thermostat housing upward. Lift out the housing. See Fig. 38 . Remove and discard O-ring seal.

Inspection

1. Check valve opening temperature. Suspend the thermostat in a pan of water. Gradually heat the water until the thermostat begins to open. Check the water temperature immediately after the thermostat opens.

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Replace the thermostat if it does not open within specifications. Starts to open temperature:

New 182°-190° F (84°-88° C)

Used 180°-192° F (83°-89° C)

2. Inspect thermostat sealing surfaces for leaks.

Installation

1. Install a new O-ring seal. Position the thermostat with the housing. Install the thermostat with housing: See Fig. 38 .

2. Lubricate the extension housing O-rings with coolant. See Fig. 39 .

3. Install O-rings on extension housing.

4. Install extension housing on thermostat housing. See Fig. 40 .

NOTE: It may be necessary to lift engine with floor jack to allow extension housing to be installed over radiator.

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Fig. 39: Lubricating & Installing Thermostat Extension Housing Courtesy of GENERAL MOTORS CORP.

Fig. 40: Installing Thermostat Extension Housing Bolt Courtesy of GENERAL MOTORS CORP.

5. Install extension housing bolt.

6. Install the radiator hose to thermostat extension pipe.

7. Install intake manifold.

8. Install intake plenum. See 3.0L DOHC V6 SATURN "L" SERIES article in ENGINE.

9. Fill and bleed air from the cooling system. See COOLING SYSTEM under BLEEDING.

WATER PUMP

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Removal

1. Disconnect the negative battery cable.

2. Remove air cleaner inlet duct from throttle body. See Fig. 41 .

3. Raise and support vehicle.

4. Remove left front wheel. See Fig. 42 .

Fig. 41: Removing Air Cleaner Inlet Duct Courtesy of GENERAL MOTORS CORP.

NOTE: Do not remove cap or open cooling system drain s from a hot system. Allow system to cool first. Be sure the vehicle is secure ly supported. To help avoid personal injury when a vehicle is on a hoist , prov ide additional support for the vehicle on the opposite end from which components a re being removed.

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Fig. 42: Removing Left Front Wheel, Splash Shield Courtesy of GENERAL MOTORS CORP.

5. Remove splash shield bolts.

6. Remove splash shield.

7. Lower vehicle.

8. Loosen water pump pulley and power steering pump pulley attachment bolts. The accessory drive belt tension provides resistance to enable loosening of the water pump pulley bolts. Do not remove the bolts at this time.

9. Install engine supported fixture (3 bar) and engine support adapter to support engine weight. See Fig. 43 .

10. Remove accessory drive belt. Removal of drive belt requires removal of right front engine mount. See Fig. 44 .

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Fig. 43: Identifying Engine Support Fixture Courtesy of GENERAL MOTORS CORP.

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Fig. 44: Removing Engine Accessory Drive Belt Courtesy of GENERAL MOTORS CORP.

11. Release plastic retaining tabs on wiring harness channel on front cover and remove cover. Use cation with releasing retaining tabs to reduce risk of breakage when removing wiring harness cover.

12. Note wiring harness routing. Remove wiring harness from channel.

13. Remove water pump pulley bolt.

14. Remove water pump pulley.

15. Remove power steering pump pulley bolts.

16. Remove power steering pump pulley.

17. Remove accessory drive belt tensioner bolts. See Fig. 45 .

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Fig. 45: Removing Engine Accessory Drive Belt Tensioner Bolts Courtesy of GENERAL MOTORS CORP.

18. Remove accessory drive belt tensioner.

19. Remove front timing belt cover bolts. See Fig. 46 .

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Fig. 46: Removing Front Timing Belt Cover Bolts Courtesy of GENERAL MOTORS CORP.

20. Remove front timing belt cover.

21. Inspect sealing strip on outer edge of front timing belt cover for cracks and/or tears.

22. Remove water pump and O-ring seal. See Fig. 47 .

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Fig. 47: Removing Water Pump Bolts Courtesy of GENERAL MOTORS CORP.

Installation

1. Install new O-ring seal. Install water pump.See Fig. 47 .

2. Install water pump bolts. See Fig. 47 .

3. Install front timing belt cover. See Fig. 46 .

4. Install front timing belt cover bolts.

5. Install accessory drive belt tensioner. Install accessory drive belt tensioner bolts. See Fig. 45 .

6. Install power steering pump pulley and water pump pulley.

7. Install power steering pump pulley bolts and water pump pulley bolts.

8. Snug power steering pump pulley and water pump pulley bolts, the bolts will be torqued when accessory drive belt is installed.

9. Route wiring harness into wiring harness channel.Install wiring harness channel.

10. Install wiring harness channel extension to right lower side of wiring harness channel

11. Install accessory drive belt. See Fig. 44 .

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12. Tighten water pump pulley and power steering pump pulley bolts.

13. Remove the engine support fixture and engine support fixture adapter. See Fig. 43 .

14. Raise and support vehicle.

15. Install splash shield. See Fig. 42 .

16. Install splash shield bolts. Tighten splash shield bolts until seated. Do not strip bolts.

17. Install right front wheel.

18. Lower vehicle, install air cleaner assembly, and reconnect the battery. See Fig. 48 .

Fig. 48: Identifying Upper Air Cleaner Housing Courtesy of GENERAL MOTORS CORP.

19. Fill and bleed air from the cooling system. See COOLING SYSTEM under BLEEDING.

TORQUE SPECIFICATIONS

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TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)Accessory Drive Belt Tensioner Bolt 30 (40)Battery Hold-Down Bracket 15 (20)Battery Terminal Bolts 13 (17)Power Steering Pump Pulley Bolts 15 (20)Thermostat Housing Bolt 15 (20)Upper Transaxle Cooler Line-to-Radiator End tank 18 (25)Water Pump Bolt 18 (25)Wheel Bolt

Step 1 46 (63)Step 2 92 (125)

INCH Lbs. (N.m) Condenser-to-Radiator Bolts 35 (4)Condenser Block-to-Radiator End Tank Bolt 35 (4)Fan Shroud-to-Radiator Bolts 35 (4)Front Timing Belt Cover Bolt 71 (8)Lower Transaxle Cooler Line-to-Radiator End Tank 35 (4)Power Steering Fluid Reservoir-to-Fan Shroud Bolts 44 (5)Radiator Bracket-to-Rail Bolts 53 (6)Splash Shield Bolts 44 (5)Water Pump Mount & Heat Shield Block Bolt 71 (8)Water Pump Pulley Bolts 71 (8)

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2000 01 engine cooling

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