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Engine Cooling System - Alternative Fuel Chevrolet Chevy Express G3500

Cooling System (Mechanical) ~1270 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
P-Clamp Mounting Nut4 N.m35 lb in
P-Clamp Mounting Bolt10 N.m89 lb in
P-Clamp Self-Tapping Screw7 N.m62 lb in

Fastener Tightening Specifications

Tools Required

J 39529 Heater Hose Pliers. See Special Tools and Equipment .

Removal Procedure

  1. Remove the bolt from coolant recovery reservoir.
  2. Set aside the coolant recovery reservoir.
  3. Partially drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  4. Remove the high pressure regulator (HPR) inlet hose (1) clamp from the tee fitting (7) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  5. Disconnect the HPR inlet hose (1) from the tee fitting (7).
  6. Remove the HPR coolant hose P-clamp bolts (3).
  7. Remove the HPR inlet hose (1) clamp using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  8. Disconnect the HPR inlet hose (1) from the fitting.
  9. Drain any remaining coolant from the hose into a suitable container.
  10. Remove the underbody coolant hose P-clamp bolts (1-5) observing their location.
  11. Pull the coolant hose out from under the underbody heat shield (3).

Installation Procedure

  1. Route the coolant hose through the underbody heat shield (3).
  2. Connect the HPR inlet hose and clamp to the fitting (1) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  3. Install the HPR hose P-clamps and mounting screws (3). Tighten: Tighten the self-tapping mounting screw to 7 N.m (62 lb in). Tighten the U-nut mounting screw to 10 N.m (89 lb in).
  4. Attach the P-clamps and hoses to the underbody at their previously observed location. Tighten: Tighten the P-clamp mounting screws to 4 N.m (35 lb in).
  5. Connect the HPR inlet hose and clamp (1) to the tee fitting (7) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  6. Position the coolant recovery reservoir and install the mounting bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
  7. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  8. Verify that the system has no leaks.

J 39529 Heater Hose Pliers. See Special Tools and Equipment .

  1. Remove the bolt from coolant recovery reservoir.
  2. Set aside the coolant recovery reservoir.
  3. Partially drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  4. Remove the high pressure regulator (HPR) inlet hose (1) clamp from the tee fitting (7) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  5. Disconnect the HPR inlet hose (1) from the tee fitting (7).
  6. Remove the HPR coolant hose P-clamp bolts (3).
  7. Remove the HPR inlet hose (1) clamp using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  8. Disconnect the HPR inlet hose (1) from the fitting.
  9. Drain any remaining coolant from the hose into a suitable container.
  10. Remove the underbody coolant hose P-clamp bolts (1-4) observing their location.
  11. Remove the hose from the vehicle.
  1. Connect the HPR inlet hose and clamp to the fitting (1) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  2. Install the HPR hose P-clamps and mounting screws (3). Tighten: Tighten the mounting bolt to 10 N.m (89 lb in). Tighten the mounting nut to 4 N.m (35 lb in).
  3. Attach the P-clamps and hoses to the underbody at their previously observed location. Tighten: Tighten the P-clamp mounting nuts to 4 N.m (35 lb in). Tighten the self-tapping mounting screw to 7 N.m (62 lb in).
  4. Connect the HPR inlet hose and clamp (1) to the tee fitting (7) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  5. Position the coolant recovery reservoir and install the mounting bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
  6. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  7. Verify that the system has no leaks.

J 39529 Heater Hose Pliers. See Special Tools and Equipment .

  1. Remove the bolt from coolant recovery reservoir.
  2. Set aside the coolant recovery reservoir.
  3. Partially drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  4. Remove the high pressure regulator (HPR) outlet hose (2) clamp from the tee fitting (5) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  5. Disconnect the HPR outlet hose (2) from the tee fitting (5).
  6. Remove the HPR coolant hose P-clamp bolts (3).
  7. Remove the HPR outlet hose (2) clamp using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  8. Disconnect the HPR outlet hose (2) from the fitting.
  9. Drain any remaining coolant from the hose into a suitable container.
  10. Remove the underbody coolant hose P-clamp bolts (1-5) observing their location.
  11. Pull the coolant hose out from under the underbody heat shield (3).
  1. Route the coolant hose through the underbody heat shield (3).
  2. Connect the HPR outlet hose and clamp to the fitting (2) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  3. Install the HPR hose P-clamps and mounting screws (3). Tighten: Tighten the self-tapping mounting screw to 7 N.m (62 lb in). Tighten the U-nut mounting screw to 10 N.m (89 lb in).
  4. Attach the P-clamps and hoses to the underbody at their previously observed location. Tighten: Tighten the P-clamp mounting screws to 4 N.m (35 lb in).
  5. Connect the HPR outlet hose and clamp (3) to the tee fitting (5) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  6. Position the coolant recovery reservoir and install the mounting bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
  7. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  8. Verify that the system has no leaks.

J 39529 Heater Hose Pliers. See Special Tools and Equipment .

  1. Remove the bolt from coolant recovery reservoir.
  2. Set aside the coolant recovery reservoir.
  3. Partially drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  4. Remove the high pressure regulator (HPR) outlet hose (2) clamp from the tee fitting (5) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  5. Disconnect the HPR outlet hose (2) from the tee fitting (5).
  6. Remove the HPR coolant hose P-clamp bolts (3).
  7. Remove the HPR outlet hose (2) clamp using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  8. Disconnect the HPR outlet hose (2) from the fitting.
  9. Drain any remaining coolant from the hose into a suitable container.
  10. Remove the underbody coolant hose P-clamp bolts (1-4) observing their location.
  11. Remove the hose from the vehicle.
  1. Connect the HPR outlet hose and clamp to the fitting (2) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  2. Install the HPR hose P-clamps and mounting screws (3). Tighten: Tighten the mounting bolt to 10 N.m (89 lb in). Tighten the mounting nut to 4 N.m (35 lb in).
  3. Attach the P-clamps and hoses to the underbody at their previously observed location. Tighten: Tighten the P-clamp mounting nuts to 4 N.m (35 lb in). Tighten the self-tapping mounting screw to 7 N.m (62 lb in).
  4. Connect the HPR outlet hose and clamp (2) to the tee fitting (5) using the J 39529 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system-alternative-fuel) .
  5. Position the coolant recovery reservoir and install the mounting bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
  6. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling in the G/H Van Service Manual.
  7. Verify that the system has no leaks.

Special Tools

Special Tools Illustration Tool Number/Description J 39529 Heater Hose Pliers

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