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 system. 2001 Saturn L300 2000-01 ENGINE COOLING Removal & Installation - L Series (V6) 2001 Saturn L300 2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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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)
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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 .
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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 .
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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.
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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 .
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)
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 .
2001 Saturn L300
2000-01 ENGINE COOLING Removal & Installation - L Series (V6)