Monday, March 21, 2011

2004 Buick Rendezvous 2wd details?


Coolant level sensor:---

Click image to see an enlarged view

Fig. Engine coolant level sensor on 3.4L & 3.8L


Coolant temperature sensor:---

3.4L Engine




NOTE
Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Drain the coolant below the level of the Engine Coolant Temperature (ECT) sensor.
  2. Disconnect the sensor electrical connector.
  3. Carefully remove the ECT sensor.

    Click image to see an enlarged view

    Fig. Removal and installation of the coolant temperature sensor


To install:


NOTE
Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.


NOTE
Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Coat the threads with sealer P/N 9985253 or equivalent.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the ECT sensor and tighten the sensor to 15 lb-ft (20 Nm).
  3. Connect the ECT sensor electrical connector.
  4. Refill the cooling system

3.6L Engine




CAUTION
Allow sufficient time for the engine to cool before removing the ECT sensor. A hot engine may cause an excessive coolant loss or a personal injury.

  1. Partially drain the cooling system.
  2. Remove the coolant temperature sensor electrical connector.
  3. Remove the coolant temperature sensor.

    Click image to see an enlarged view

    Fig. Removal and installation of the coolant temperature sensor


To install:

  1. Install the coolant temperature sensor and tighten it to 16 ft. lbs. (22 Nm).
  2. Install the coolant temperature sensor electrical connector.
  3. Inspect and fill the cooling system as necessary.

Engine fan:---

Removal & Installation




CAUTION
An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.


CAUTION
To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

  1. Remove the air cleaner and duct assembly.
  2. Remove the cooling fan harness electrical connector.
  3. Remove right side diagonal brace.
  4. Loosen the engine mount strut nuts.
  5. Remove the engine mount strut bracket brace bolts from the upper radiator support and rotate the struts and brackets rearward.
  6. Remove upper radiator hose.
  7. Remove the radiator upper mount bolts.
  8. Remove the radiator upper mounts.
  9. Remove the cooling fan shroud bolts.
  10. Reposition the coolant overflow hose clamp at the radiator using the special tool J 38185.
  11. Disconnect and reposition the coolant overflow hose.
  12. Disconnect the upper TOC line from the radiator.
  13. Raise the vehicle.
  14. Disconnect the TOC lines from the fan module retainer clip.
  15. Lower the vehicle.
  16. Disconnect the engine wiring harness retainers at the engine harness bracket.

    Click image to see an enlarged view

    Fig. Removal and installation of the wiring harness retainers (arrow)

  17. Reposition the engine wiring harness. Remove the cooling fans with the cooling fan shroud.

To install

  1. Install the cooling fans with the cooling fan shroud.
  2. Reposition the engine wiring harness.
  3. Connect the engine wiring harness retainers at the engine harness bracket.
  4. Raise the vehicle.
  5. Connect the TOC lines to the fan module retainer clip.
  6. Lower the vehicle.
  7. Connect the upper TOC line to the radiator.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  8. Install the cooling fan shroud bolts and tighten them to 53 inch lbs. (6 Nm).
  9. Install the radiator upper mounts.
  10. Install the radiator upper mount bolts and tighten them to 88 inch lbs. (10 Nm).
  11. Install the coolant overflow hose to the radiator.
  12. Reposition the hose clamp to secure the coolant overflow hose using the special tool J 38185.
  13. Install the upper radiator hose.
  14. Position the engine mount struts brackets flush with the upper radiator support.
  15. Install the engine mount strut bracket brace bolts to the upper radiator support and tighten them to 21 ft. lbs. (28 Nm).
  16. Tighten the engine mount strut nuts to 35 ft. lbs. (48 Nm).
  17. Install right side diagonal brace.
  18. Install the cooling fan harness electrical connector.
  19. Install the air cleaner and duct assembly.



Radiator:------------
  1. Recover the refrigerant from the A/C system.
  2. Drain the cooling system.
  3. Remove the cooling fans with the cooling fan shroud.
  4. Reposition the hose clamp at the water pump housing using the special tool J 38185
  5. Disconnect the radiator outlet hose from the water pump housing.
  6. Raise the vehicle.
  7. Reposition the hose clamp at the radiator using special tool J 38185.
  8. Disconnect the radiator outlet hose from the radiator.
  9. Remove the radiator outlet hose.
  10. Disconnect the lower TOC line from the radiator.
  11. Lower the vehicle.
  12. Remove the nut which secures the A/C discharge hose to the condenser block.
  13. Disconnect the A/C discharge hose from the condenser block.
  14. Remove and discard the sealing washer.
    NOTE
    Cap or tape off the open A/C hose immediately to prevent system contamination.

  15. Cap or tape off the A/C discharge hose.
  16. Remove the bolt which secures the evaporator inlet tube to the condenser block.
  17. Disconnect the evaporator inlet tube from the condenser block.
  18. Cap or tape off the evaporator inlet tube.
  19. Remove the radiator and condenser assembly.
  20. Remove the condenser tube clip bolt.
  21. Remove the condenser mounting bolts.
  22. Remove the condenser from the radiator.

To install

  1. Install the condenser to the radiator.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the mounting bolts that secure the condenser to the radiator and tighten them to 53 inch lbs. (6 Nm).
  3. Install the condenser tube clip bolt and tighten to 22 inch lbs. (2.5 Nm).
  4. Install the radiator and condenser assembly.
  5. Remove the cap or the tape from the evaporator inlet tube.
  6. Install a new seal washer to the evaporator inlet tube.
  7. Install the evaporator inlet tube and the bolt to the condenser block and tighten them to 12 ft. lbs. (16 Nm).
  8. Remove the cap or the tape from the A/C discharge hose.
  9. Install a new sealing washer to the A/C discharge hose.
  10. Install the A/C discharge hose and the nut to the condenser block and tighten the nut to 12 ft. lbs. (16 Nm).
  11. Raise the vehicle.
  12. Connect the lower TOC line to the radiator.
  13. Install the radiator outlet hose.
  14. Connect the radiator outlet hose to the radiator.
  15. Reposition the hose clamp at the radiator to secure the hose using special tool J 38185.
  16. Lower the vehicle.
  17. Connect the radiator outlet hose to the water pump housing.
  18. Reposition the hose clamp at the water pump housing to secure the hose using the special tool J 38185.
  19. Install the cooling fans with the cooling fan shroud..
  20. Fill the cooling system.
  21. Evacuate and recharge the A/C system.
  22. Leak test the fittings of the component using the special tool J 38185.
  23. Inspect the transmission fluid level.

  1. Recover the refrigerant from the A/C system.
  2. Drain the cooling system.
  3. Remove the cooling fans with the cooling fan shroud.
  4. Reposition the hose clamp at the water pump housing using the special tool J 38185
  5. Disconnect the radiator outlet hose from the water pump housing.
  6. Raise the vehicle.
  7. Reposition the hose clamp at the radiator using special tool J 38185.
  8. Disconnect the radiator outlet hose from the radiator.
  9. Remove the radiator outlet hose.
  10. Disconnect the lower TOC line from the radiator.
  11. Lower the vehicle.
  12. Remove the nut which secures the A/C discharge hose to the condenser block.
  13. Disconnect the A/C discharge hose from the condenser block.
  14. Remove and discard the sealing washer.
    NOTE
    Cap or tape off the open A/C hose immediately to prevent system contamination.

  15. Cap or tape off the A/C discharge hose.
  16. Remove the bolt which secures the evaporator inlet tube to the condenser block.
  17. Disconnect the evaporator inlet tube from the condenser block.
  18. Cap or tape off the evaporator inlet tube.
  19. Remove the radiator and condenser assembly.
  20. Remove the condenser tube clip bolt.
  21. Remove the condenser mounting bolts.
  22. Remove the condenser from the radiator.

To install

  1. Install the condenser to the radiator.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the mounting bolts that secure the condenser to the radiator and tighten them to 53 inch lbs. (6 Nm).
  3. Install the condenser tube clip bolt and tighten to 22 inch lbs. (2.5 Nm).
  4. Install the radiator and condenser assembly.
  5. Remove the cap or the tape from the evaporator inlet tube.
  6. Install a new seal washer to the evaporator inlet tube.
  7. Install the evaporator inlet tube and the bolt to the condenser block and tighten them to 12 ft. lbs. (16 Nm).
  8. Remove the cap or the tape from the A/C discharge hose.
  9. Install a new sealing washer to the A/C discharge hose.
  10. Install the A/C discharge hose and the nut to the condenser block and tighten the nut to 12 ft. lbs. (16 Nm).
  11. Raise the vehicle.
  12. Connect the lower TOC line to the radiator.
  13. Install the radiator outlet hose.
  14. Connect the radiator outlet hose to the radiator.
  15. Reposition the hose clamp at the radiator to secure the hose using special tool J 38185.
  16. Lower the vehicle.
  17. Connect the radiator outlet hose to the water pump housing.
  18. Reposition the hose clamp at the water pump housing to secure the hose using the special tool J 38185.
  19. Install the cooling fans with the cooling fan shroud..
  20. Fill the cooling system.
  21. Evacuate and recharge the A/C system.
  22. Leak test the fittings of the component using the special tool J 39400-A.
  23. Inspect the transmission fluid level.


Thermostat:----------

3.4L Engine



  1. Remove the air cleaner and duct assembly.
  2. Drain the coolant until the coolant level is below the thermostat.
  3. Remove the crossover exhaust pipe.
  4. Remove the radiator hose from the thermostat housing.
  5. Remove the thermostat housing bolts and clean any sealer from the bolt threads.

    Click image to see an enlarged view

    Fig. Remove the housing bolts

  6. Remove the thermostat housing and gasket.
  7. Remove the thermostat.
  8. Clean the mating surfaces.

To install:

Click image to see an enlarged view

Fig. The removal and installation of the thermostat

  1. Install the thermostat.
  2. Install the thermostat housing and gasket.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the thermostat housing bolts and tighten them to 18 ft. lbs. (25 Nm).
  4. Install the radiator hose to the thermostat housing.
  5. Install the crossover exhaust pipe.
  6. Install the air cleaner and duct assembly.
  7. Fill the cooling system.

  1. Remove the air cleaner and duct assembly.
  2. Drain the coolant until the coolant level is below the thermostat.
  3. Remove the crossover exhaust pipe.
  4. Remove the radiator hose from the thermostat housing.
  5. Remove the thermostat housing bolts and clean any sealer from the bolt threads.

    Click image to see an enlarged view

    Fig. Remove the housing bolts

  6. Remove the thermostat housing and gasket.
  7. Remove the thermostat.
  8. Clean the mating surfaces.

To install:

Click image to see an enlarged view

Fig. The removal and installation of the thermostat

  1. Install the thermostat.
  2. Install the thermostat housing and gasket.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the thermostat housing bolts and tighten them to 18 ft. lbs. (25 Nm).
  4. Install the radiator hose to the thermostat housing.
  5. Install the crossover exhaust pipe.
  6. Install the air cleaner and duct assembly.
  7. Fill the cooling system.

3.5L Engine



  1. Remove the thermostat housing.
  2. Remove the thermostat.
  3. Remove and discard the thermostat O-ring seal.
  4. Clean and inspect the thermostat housing sealing surfaces.

To install:

  1. Install a NEW thermostat O-ring seal.
  2. Install the thermostat.
  3. Install the thermostat housing.

3.6L Engine



  1. Remove the air cleaner.
  2. Remove the throttle body assembly.
  3. Remove the heater pipes.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  4. Remove the coolant inlet pipe.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  5. Remove the thermostat bolts and the thermostat.
  6. Clean the thermostat and heater pipe sealing surfaces.

    Click image to see an enlarged view

    Fig. Location of the thermostat-3.6L Engine


To install:

  1. Install a NEW thermostat gasket.
  2. Install the thermostat and gasket.
  3. Install the thermostat bolts and tighten them to 89 inch lbs. (10 Nm).
  4. Install the coolant inlet pipe.
  5. Install the heater pipes.
  6. Install the throttle body assembly.
  7. Install the air cleaner.
  8. Fill the cooling system.

  1. Remove the air cleaner.
  2. Remove the throttle body assembly.
  3. Remove the heater pipes.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  4. Remove the coolant inlet pipe.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  5. Remove the thermostat bolts and the thermostat.
  6. Clean the thermostat and heater pipe sealing surfaces.

    Click image to see an enlarged view

    Fig. Location of the thermostat-3.6L Engine


To install:

  1. Install a NEW thermostat gasket.
  2. Install the thermostat and gasket.
  3. Install the thermostat bolts and tighten them to 89 inch lbs. (10 Nm).
  4. Install the coolant inlet pipe.
  5. Install the heater pipes.
  6. Install the throttle body assembly.
  7. Install the air cleaner.
  8. Fill the cooling system.

-------------
Water pump:----------

3.4L & 3.5L Engines



  1. Drain the cooling system.
  2. Remove the drive belt guard.
  3. Loosen the water pump pulley bolts.
  4. Remove the drive belt.
  5. Remove the water pump pulley bolts.
  6. Remove the water pump pulley.
  7. Remove the water pump bolts.
  8. Remove the water pump.
  9. Remove and discard the water pump gasket.
  10. Clean the water pump mating surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the water pump-3.4L and 3.5L Engines


To install:

  1. Install a NEW water pump gasket onto the water pump.
  2. Install the water pump.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the water pump bolts and tighten the bolts to 89 inch lbs. (10 Nm).
  4. Install the water pump pulley.
  5. Install the water pump pulley bolts until snug.
  6. Install the drive belt.
  7. Tighten the water pump pulley bolts to 18 lb ft. (25 Nm).
  8. Install the drive belt guard.
  9. Fill the cooling system.

3.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the coolant from the engine.
  3. Remove or disconnect the following:

    Negative battery cable
    Serpentine drive belt guard
    Loosen the water pump pulley bolts
    Serpentine drive belt
    Water pump pulley
    Water pump
    Water pump gasket

    Click image to see an enlarged view

    Fig. Exploded view of the water pump-3.4L engine



To install:

  1. Clean the gasket mounting surfaces.
  2. Install or connect the following:

    Gasket
    Water pump. Torque the bolts to 89 inch lbs. (10 Nm).
    Water pump pulley and hand-tighten the bolts at this time
    Serpentine drive belt
    Water pump pulley bolts to 18 ft. lbs. (25 Nm)
    Serpentine drive belt guard

  3. Fill the cooling system.
  4. Start the engine and check for leaks, repair if necessary.
  5. Road test the vehicle and verify there is no air in the cooling system.

3.6L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Install the EN 46104 onto the water pump pulley.

    Click image to see an enlarged view

    Fig. EN 46104 installed-3.6L engine

  3. Remove the water pump pulley bolts.
  4. Remove the water pump pulley.
  5. Remove the water pump bolts.
  6. Remove the water pump from the front cover.
  7. Remove the water pump gasket.

To install:

  1. Ensure that the engine front cover and water pump are clear of old gasket material.
  2. Place a new water pump gasket on the water pump.
  3. Place the water pump in position on the front cover.
  4. Install the water pump bolts. Tighten the water pump bolts to 89 inch lbs. (10 Nm).
  5. Install the water pump pulley.
  6. Loosely install the water pump pulley bolts.
  7. Install the EN 46104 onto the water pump pulley. Tighten the water pump pulley bolts to 89 inch lbs. (10 Nm).

  1. Drain the cooling system until the coolant is below the water pump.
  2. Remove the accessory drive belt from the water pump.
  3. Use the EN 46104 tool in order to retain the water pump pulley.

    Click image to see an enlarged view

    Fig. EN 46104 installed-3.6L engine

  4. Remove the water pump pulley bolts and the water pump pulley.
  5. Remove the water pump bolts.
  6. Remove the water pump.
  7. Remove and discard the water pump gasket.
  8. Clean the water pump sealing surfaces.

To install:

  1. Install the NEW water pump gasket.
  2. Install the water pump.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install and tighten the water pump bolts to 89 inch lbs. (10 Nm).
  4. Install the water pump pulley.
  5. Use the EN 46104 tool in order to retain the water pump pulley.
  6. Install and tighten the water pump pulley bolts to 106 inch lbs. (12 Nm).
  7. Install the accessory drive belt.
  8. Fill the cooling system.