Radiator Chevrolet Chevy Van G3500

Removal Procedure

1. Partially drain the coolant. Refer to «COOLING SYSTEM DRAINING AND FILLING»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) .
2. Remove the air cleaner and the duct.
3. Remove the coolant recovery reservoir or the surge tank (Diesel). For the reservoir, refer to «COOLANT RECOVERY RESERVOIR REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) . For the surge tank, refer to «SURGE TANK (DIESEL)»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) .
4. Remove the upper fan shroud.
5. Remove the lower fan shroud.
6. Remove the fan and the clutch from the engine. Refer to «FAN CLUTCH REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) .
7. Disconnect the electrical connections from the radiator.
8. Disconnect the clamps and the upper and the lower hoses from the radiator.
9. Disconnect the transmission oil cooler lines from the radiator. Refer to Oil Cooler Line Replacement in Automatic Transaxle.
10. Disconnect the oil cooler lines from the radiator. Refer to «OIL COOLER HOSE/PIPE REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) .
11. Remove the radiator.

INSTALLATION PROCEDURE

1. Install the radiator.
2. Install the oil cooler lines to the vehicle. Refer to «OIL COOLER HOSE/PIPE REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator).
3. Install the transmission oil cooler lines. Refer to Oil Cooler Lines Replacement in Automatic Transaxle.
4. Connect the clamps and the upper and the lower hoses to the radiator.
5. Install the electrical connections to the radiator.
6. Install the fan and the clutch to the engine. Refer to «FAN CLUTCH REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator).
7. Install the lower fan shroud. (Scheme 1)
8. Install the upper fan shroud. Tighten Tighten the upper and the lower fan shroud retaining bolts to 11 N.m (97 lb ft). 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.
9. Install the coolant recovery reservoir or the surge tank. For the reservoir, refer to «COOLANT RECOVERY RESERVOIR REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator). For the surge tank, refer to «SURGE TANK (DIESEL)»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator).
10. Install the air cleaner and the duct.
11. Refill the coolant. Refer to «COOLING SYSTEM DRAINING AND FILLING»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator).

Note. When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Remove the recovery reservoir hose clamp and the hose at the radiator overflow fitting.
2. Remove the reservoir retaining bolt.
3. Remove the coolant recovery reservoir from the cowl tabs.
4. Remove the coolant reservoir from the vehicle.
5. Clean the coolant reservoir with soap and water.
6. Rinse the coolant reservoir with clean water.

1. Install the coolant recovery reservoir to the cowl tabs.
2. Install the reservoir retaining bolt. (Scheme 3) Tighten Tighten the coolant reservoir bolt to 11 N.m (97 lb in). 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 reservoir hose clamp and the hose at the radiator overflow fitting. (Scheme 2)
4. Fill the reservoir with coolant to the proper level. Refer to «COOLING SYSTEM DRAINING AND FILLING»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator).

Scheme 1

1. Remove the surge tank hose clamp and the hose at the radiator overflow fitting.
2. Remove the surge tank retaining bolt.
3. Remove the surge tank from the cowl tabs.
4. Remove the surge tank from the vehicle.
5. Clean the surge tank with soap and water.
6. Rinse the surge tank with clean water.

1. Install the surge tank to the cowl tabs. see scheme 4
2. Install the surge tank retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 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 surge tank hose clamp and the hose at the radiator overflow fitting.
4. Fill the surge tank with coolant to the proper level. Refer to Cooling System Draining and Filling.

1. Remove the air cleaner and the duct.
2. Remove the coolant recovery reservoir or the surge tank (Diesel). For the reservoir, refer to «COOLANT RECOVERY RESERVOIR REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) . For the surge tank, refer to «SURGE TANK (DIESEL)»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) .
3. Remove the upper radiator shroud.
4. For the 4.3L, 5.0L, and the 5.7L, remove the fan and the clutch retaining nut from the coolant pump pulley.
5. Remove the fan and the clutch from the vehicle.
6. For the 7.4L, remove the fan and the clutch retaining nuts from the coolant pump pulley.
7. Remove the fan and the clutch from the vehicle.
8. For the diesel engines, remove the fan and the clutch retaining nuts from the coolant pump pulley.
9. Remove the fan and the clutch from the vehicle.

1. For the 4.3L, 5.0L, and the 5.7L, install the fan and the clutch to the vehicle.
2. Install the fan and the clutch retaining nut to the coolant pump pulley. Tighten Tighten the nut to 57 N.m (42 lb ft). 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. For the 7.4L, install the fan and the clutch to the vehicle.
4. Install the fan and the clutch retaining nuts to the coolant pump pulley. Tighten Tighten the nuts to 57 N.m (42 lb ft).
5. For the diesel engines, install the fan and the clutch to the vehicle.
6. Install the fan and the clutch retaining nuts to the coolant pump pulley. Tighten Tighten the nuts to 24 N.m (18 lb ft).
7. Install the upper radiator shroud.
8. Install the coolant reservoir or the surge tank (Diesel). For the reservoir, refer to «COOLANT RECOVERY RESERVOIR REPLACEMENT»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) . For the surge tank, refer to «SURGE TANK (DIESEL)»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator) .
9. Install the air cleaner and the duct.

Scheme 2

1. Remove the oil cooler line retainers from the frame.
2. For the 4.3L with auxiliary oil cooler only, remove the oil cooler line retaining bolt from the oil filter base.
3. In order to remove the retaining ring (E-clips) securing the cooler line to the quick connect fitting, be sure to use the following procedure
4. Pull the plastic cap back from the quick connect fitting and down along the cooler line about two inches.
5. You will need a bent-tip screwdriver in order to remove the retaining ring.
6. Using the bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting.
7. Rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.
8. Remove the retaining ring from the quick connect fitting.
9. Discard the retaining ring.
10. Pull the cooler line straight out from the quick connect fitting.
11. Repeat steps 3 through 10 in order to remove the oil cooler lines from the oil filter base.
12. Repeat steps 3 through 10 in order to remove the remaining cooler lines from the remaining quick connect fittings, such as those on the radiator and the auxiliary cooler.

Scheme 3

1. Install a new retaining ring (E-clip) onto each quick connect fitting using the following procedure
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
4. Ensure the three retaining ring ears can be seen from inside the fitting and the retaining ring can move freely in the fitting slots.
5. Use the above procedure to install retaining rings onto all quick connect fittings. NOTE: Ensure the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a NEW plastic cap and position the cap on the cooler line prior to cooler line installation.
6. Connect the oil cooler lines to the radiator and the auxiliary cooler. Repeat steps 1 through 5. see scheme 10
7. Install the oil cooler lines to the oil filter base. Repeat steps 1 through 5.
8. For the 4.3L with auxiliary oil cooler only, install the oil cooler line retaining bolt to the oil filter base. see scheme 7 Tighten Tighten the oil cooler line retaining bolt to the oil filter base to 35 N.m (26 lb ft). 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.
9. Install the oil cooler line retainers to the frame.
10. Install the oil cooler line retaining bolt. Tighten Tighten the oil cooler line retaining bolt to 12 N.m (106 lb in).
11. Check the oil level. Fill the oil as necessary. Refer to «COOLING SYSTEM DRAINING AND FILLING»(/chevrolet/chevy-van-g3500/1985-1999/remont/cooling-system-mechanical/#radiator).

ENGINE COOLANT RECYCLING

Tools Required

GM approved Recycling System such as Pro Clean

Whenever the cooling system needs maintenance or repairs, remove and replace the coolant with qualified new or recycled coolant.

If you only drain the radiator, up to 50 percent of the used, contaminated coolant can remain in the cooling system.

Use any of the following methods in order to remove the coolant

1. Use a waterless coolant evacuation system, available in the GM Dealer Equipment program, or equivalent, that removes the used coolant and replaces the coolant with new or recycled coolant.
2. Use a GM approved coolant recycling system, available in the GM Dealer Equipment program, or equivalent, that recycles the coolant on the vehicle. This eliminates the need for coolant evacuation. IMPORTANT: Do not recycle coolant on vehicles manufactured with GM Goodwrench Dex-Cool.
3. Recover the used coolant. Store the coolant in a used coolant holding tank. Submit the used coolant for recycling on a regular basis.

DRAINING PROCEDURE

Note. When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Allow the engine to cool completely.
2. Place a drain pan under the radiator drain cock.
3. Install a tube on the radiator drain. Place the end of the tube in the drain pan.
4. After the engine cools down, remove the radiator cap.
5. Completely open the radiator drain cock.
6. Allow the coolant to drain from the system until the flow stops.
7. Place a drain pan under the block drain hole plug.
8. Remove the drain hole plug from the engine block.
9. Allow the coolant to drain from the block until the flow stops. There may be more drainage from the radiator at this time.
10. Install the block drain hole plug.
11. Close the radiator drain cock.

FILLING PROCEDURE

1. Check to make sure that the radiator drain cock is closed.
2. Check to make sure that the block drain hole plug is tight.
3. Premix a 50/50 solution of antifreeze and clear, preferably distilled water. If you use the old coolant, make sure the solution is clean and clear, and that the solution is a 50/50 mixture of glycol and water.
4. Place a large top funnel in the radiator filler neck.
5. Slowly pour in the coolant. Because the thermostat is closed, filling the cooling system may be slow.
6. After you fill the cooling system to 13 mm (1/2 in) below the radiator filler neck, start the engine and let the cooling system warm up. When the thermostat opens, the coolant level may drop. If the level drops, add coolant to just below the filler neck.
7. Install the radiator cap.
8. Check the coolant level in the coolant recovery reservoir. Add coolant as necessary.

See also:
• COOLING SYSTEM DRAINING AND FILLING