Engine Cooling System: Removal & Installation Chevrolet RV Cutaway G3500

Removal Procedure

1. Partially drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Disconnect the hose from the coolant recovery reservoir.
3. Remove the coolant recovery reservoir retaining screws.
4. Remove the coolant recovery reservoir.

Installation Procedure

1. Install the coolant recovery reservoir.
2. Install the coolant recovery reservoir retaining screws. Tighten: Tighten the screws to 6 N.m (53 lb in).
3. Connect the hose to the coolant recovery reservoir.
4. Add coolant to reservoir. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Reposition the clamp at the radiator inlet using the J 38185 .
3. Reposition the clamp at the thermostat housing using the J 38185 .
4. Remove the radiator inlet hose from the radiator.
5. Remove the radiator inlet hose from the thermostat housing.
6. Remove the radiator inlet hose (5).

1. Install the radiator inlet hose (5).
2. Install the radiator inlet hose to the radiator.
3. Install the radiator inlet hose to the thermostat housing.
4. Position the hose clamp at the thermostat housing using the J 38185 .
5. Position the hose clamp at the radiator inlet housing using the J 38185 .
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Remove the clamp at the radiator outlet using the J 38185 .
3. Remove the radiator outlet hose clamp at the engine using the J 38185 .
4. Remove the radiator outlet hose clamp at the coolant recovery reservoir using the J 38185 .
5. Remove the radiator outlet hose from the coolant recovery reservoir.
6. Remove the radiator outlet hose from the radiator.
7. Remove the radiator outlet hose from the engine.
8. Remove the radiator outlet hose (4).

1. Install the radiator outlet hose (4).
2. Install the radiator outlet hose to the engine.
3. Install the radiator outlet hose to the radiator.
4. Install the radiator outlet hose to the coolant recovery reservoir.
5. Install the radiator outlet hose clamp to the coolant recovery reservoir using the J 38185 .
6. Install the radiator outlet hose clamp to the engine using the J 38185 .
7. Install the radiator outlet clamp to the radiator outlet using the J 38185 .
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Drain the coolant from the reservoir. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
3. Remove the vent hose from the throttle body.
4. Remove the vent hose from the radiator.
5. Remove the vent hose (1) from the vehicle.

1. Install the vent hose (1) to the vehicle.
2. Connect the vent hose to the radiator.
3. Connect the vent hose to the throttle body.
4. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
5. Fill the reservoir with coolant. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe.
2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings.
4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors.
5. Clean all of the components in a suitable solvent, and dry them with compressed air.
6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary.

1. Install a new retaining ring into each quick connector fitting.
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector.
3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots.
5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection.
6. Snap the plastic cap onto the quick connect fitting.
7. Ensure that the plastic cap is fully seated against the fitting.
8. Ensure that no gap is present between the cap and the fitting.
9. Inspect and fill the engine oil to the proper level.

The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable.

1. Disconnect the cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-197849-S33802894482005101300000) .
2. Open the oil cooler hose clip located on the lower fan shroud.
3. Remove the oil cooler hoses from the clip.
4. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings.
5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197837-S12044229642005101300000) in General Information.
6. Remove the oil cooler hose bracket bolt (1).
7. Remove the oil cooler hose adapter bolts (2).
8. Remove the oil cooler hose assembly and gasket.
9. Discard the gasket.
10. Inspect the fittings, connectors and cooler hoses for damage or distortion.

1. Install the oil cooler hose assembly and a new gasket.
2. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Install the oil cooler hose bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Install the oil cooler hoses to the hose clip on the fan shroud.
5. Snap the oil cooler hose clip shut.
6. Connect the oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-197849-S33802894482005101300000) .
7. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting.

1. Open the hood.
2. Disconnect the oil cooler lines from the auxiliary oil cooler. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-197849-S33802894482005101300000)
3. Remove the auxiliary oil cooler from the vehicle.

1. Install the auxiliary oil cooler.
2. Connect the oil cooler lines to the vehicle. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-197849-S33802894482005101300000) .
3. Lower the vehicle.

1. If a fan assembly fails, inspect the hub and the drive components. A fan assembly may fail due to an imbalance in the hub. This type of failure may not be the fault of the blades.
2. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-197849-S02926745102005101300000) .
3. Insert the tool around the pulley in order to secure the pulley. Insert the J 41240 onto the fan clutch nut.
4. Remove the following components: The fan (1) The fan clutch (2)
5. Inspect the following components for cracks, distortion, or other damage: The belts The hub The adapter The pulley
6. Replace the components, as necessary.

1. Install the following components: The fan (1) The fan clutch (2) Tighten: Tighten the fan clutch nut to 145 N.m (107 lb ft).
2. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper»(ref-197849-S02926745102005101300000) .

1. Remove the fan shroud bolts (1) from the top of the radiator support.
2. Remove the fan shroud bolts (3) from the sides of the fan shroud.
3. Remove the upper fan shroud (2).
4. Install the tool onto the fan clutch nut. Install the J 41240 in order to secure the pulley.
5. Remove the fan clutch assembly.
6. Inspect the following components for cracks, distortion, or other damage: The belt The hub The adapter The pulley
7. Remove the bolts from the fan clutch.
8. Separate the fan clutch from the fan blade.

1. Install the fan clutch (2) to the fan blade (1).
2. Install the bolts to the fan clutch. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the fan clutch assembly to the pulley.
4. Install the tool onto the fan clutch nut. Install the J 41240 in order to secure the pulley. Tighten: Tighten the nut to 95 N.m (70 lb ft).
5. Install the upper fan shroud (2).
6. Install the fan shroud bolts (1) to the top of the radiator support. Tighten: Tighten the bolts to 6 N.m (53 lb in).
7. Install the fan shroud bolts (3) to the sides of the fan shroud. Tighten: Tighten the bolts to 6 N.m (53 lb in).

1. Remove the bolt from the coolant recovery reservoir and reposition.
2. Remove air cleaner assembly.
3. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet»(ref-197849-S19187780932005101300000) .
4. Remove the water pump inlet bolts.
5. Remove the water pump inlet and thermostat from the water pump.

1. Install the thermostat and water pump inlet to the water pump.
2. Install the water pump inlet bolts. Tighten: Tighten the water pump inlet bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet»(ref-197849-S19187780932005101300000) .
4. Install the air cleaner assembly.
5. Install the coolant recovery reservoir and bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).

1. Remove the air cleaner and the duct assembly. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-197838-S13746642502005101300000) in Engine Controls - 4.3L.
2. Partially drain the coolant. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
3. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
4. Disconnect the radiator hose from the thermostat housing.
5. Remove the bolts attaching the thermostat housing to the thermostat.
6. Remove the thermostat housing.
7. Remove the thermostat.
8. Clean the gasket mating surfaces.

Note. Refer to Coolant Addition Notice in Cautions and Notices.

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold.
3. Install the bolts to the housing. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the radiator hose to the thermostat housing.
5. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
6. Install the air cleaner and the duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-197838-S13746642502005101300000) in Engine Controls - 4.3L.
7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
8. Bleed the air from the cooling system.
9. Inspect the thermostat housing and the gasket for coolant leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Remove the coolant air bleed pipe bolts (1).
3. Remove the coolant air bleed pipe (2) with gaskets (3).
4. Remove the gaskets from the coolant air bleed pipe and covers.
5. Discard the gaskets.
6. Remove the coolant air bleed hose (1) from the pipe (2).

1. Install the coolant air bleed hose (1) onto the pipe (2).
2. Install the gaskets onto the coolant air bleed pipe and covers.
3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads.
4. Install the coolant air bleed pipe bolts (1). Tighten: Tighten the coolant air bleed pipe bolts to 12 N.m (106 lb in).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
2. Remove the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-197839-S15148482972005101300000) in Engine Electrical.
3. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
4. Reposition the coolant air bleed hose clamp at the throttle body.
5. Remove the coolant air bleed hose from the throttle body.
6. Position the coolant air bleed hose clamp at the pipe.
7. Remove the coolant air bleed hose (1) from the pipe (2).

1. Install the coolant air bleed hose (1) to the pipe (2).
2. Position the coolant air bleed hose clamp at the pipe.
3. Install the coolant air bleed hose to the throttle body.
4. Position the coolant air bleed hose clamp at the throttle body.
5. Install the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-197839-S15148482972005101300000) in Engine Electrical.
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls 4.8L, 5.3L, and 6.0L.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls - 4.3L.
2. Remove the air cleaner outlet resonator duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-197838-S13746642502005101300000) in Engine Controls - 4.3L.
3. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
4. Remove the cooling fan. Refer to «Fan Replacement»(ref-197849-S00360591352005101300000) .
5. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-197858-S11147483992005101300000) in Engine Mechanical - 4.3L.
6. Reposition the radiator outlet hose clamps at the surge tank and water pump.
7. Remove the radiator outlet hose from the surge tank.
8. Remove the radiator outlet hose from the water pump.
9. Reposition the water pump inlet hose clamps.
10. Remove the water pump inlet hose.
11. Using J 41240 to hold the water pump pulley, remove the water pump pulley bolts.
12. Remove the water pump bolts.
13. Remove the water pump.
14. Remove and discard the water pump gaskets.
15. Clean and inspect the water pump, if necessary. Refer to «Water Pump Cleaning and Inspection»(ref-197858-S30747583882005101300000) in Engine Mechanical - 4.3L. Unit Repair.

1. If reusing the fasteners, apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts.
2. Install NEW water pump gaskets and the water pump. NOTE: Refer to «Fastener Notice»(ref-197832-S19142218752005101300000) in Cautions and Notices.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 45 N.m (33 lb ft).
4. Using J 41240 to hold the water pump pulley, install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
5. Install the water pump inlet hose.
6. Position the water pump inlet hose clamps.
7. Install the radiator outlet hose to the water pump.
8. Install the radiator outlet hose to the surge tank.
9. Position the radiator outlet hose clamps at the surge tank and water pump.
10. Install the drive belt. Refer to «Drive Belt Replacement»(ref-197858-S11147483992005101300000) in Engine Mechanical - 4.3L.
11. Install the cooling fan. Refer to «Fan Clutch Replacement»(ref-197849-S33585638192005101300000) .
12. Install the air cleaner outlet resonator duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-197838-S13746642502005101300000) in Engine Controls - 4.3L.
13. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls - 4.3L.
14. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
15. Inspect the cooling system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls - 4.8L, 5.3L and 6.0L.
3. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-197849-S33585638192005101300000) .
4. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-197859-S39478025542005101300000) .
5. Reposition the inlet hose clamp at the water pump.
6. Remove the inlet hose from the water pump.
7. Reposition the outlet hose clamp at the water pump.
8. Remove the outlet hose from the water pump.
9. Reposition the heater inlet hose clamp at the water pump.
10. Remove the heater inlet hose from the water pump.
11. Remove the water pump bolts.
12. Remove the water pump and gaskets.
13. Discard the water pump gaskets.

1. Install the water pump and NEW gaskets.
2. Install the water pump bolts. Tighten: Tighten the water pump bolts a first pass to 15 N.m (11 lb ft). Tighten the water pump bolts a final pass to 30 N.m (22 lb ft).
3. Install the heater inlet hose to the water pump.
4. Position the heater inlet hose clamp at the water pump.
5. Install the outlet hose to the water pump.
6. Position the outlet hose clamp at the water pump.
7. Install the inlet hose to the water pump.
8. Position the inlet hose clamp at the water pump.
9. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-197859-S39478025542005101300000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
10. Install the fan blade and clutch assembly. Refer to «Fan Clutch Replacement»(ref-197849-S33585638192005101300000) .
11. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls - 4.8L, 5.3L and 6.0L.
12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls 4.8L, 5.3L, 6.0L or «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls 4.3L.
3. Remove the fan shroud bolts (1,3,4).
4. Remove the fan shroud (2,5).

1. Install the fan shroud (2,5).
2. Install the fan shroud bolts (1,3,4). Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls 4.8L, 5.3L, 6.0L or «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls 4.3L.
4. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls 4.8L, 5.3L, 6.0L or «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls 4.3L.
3. Remove the fan shroud bolts (1,3,4).
4. Remove the fan shroud (2,5).

1. Install the fan shroud (2,5).
2. Install the fan shroud bolts (1,3,4). Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls 4.8L, 5.3L, 6.0L or «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls 4.3L.
4. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls - 4.8L, 5.3L, 6.0L or «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls - 4.3L.
2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
3. Remove the clamp at the radiator inlet using the J 38185 .
4. Remove the radiator inlet hose (5) from the radiator.
5. Remove the outlet heater hose clamp at the radiator using the J 38185 .
6. Remove the outlet heater hose (2) from the radiator.
7. Remove the automatic transmission cooler lines. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-197869-S02118700822005101300000) or «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-197870-S11316037832005101300000) in Automatic Transmission.
8. Remove the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-197849-S33802894482005101300000) .
9. Remove the fan shroud bolts (1) from the top of the radiator support.
10. Remove the fan shroud bolts (3) from the sides of the fan shroud.
11. Remove the radiator (2).
12. Remove the radiator insulators (1, 3).
13. Inspect the following components: The radiator The insulators The hoses and clamps The mounting hardware Replace the components as necessary.

1. Install the radiator insulators (1, 3).
2. Install the radiator (2).
3. Install the fan shroud bolts (1) to the top of the radiator support. Tighten: Tighten the bolts to 6 N.m (53 lb in).
4. Install the fan shroud bolts (3) to the sides of the fan shroud. Tighten: Tighten the bolts to 6 N.m (53 lb in).
5. Install the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-197849-S33802894482005101300000) .
6. Install the automatic transmission oil cooler lines. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-197869-S02118700822005101300000) or «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-197870-S11316037832005101300000) in Automatic Transmission.
7. Install the radiator inlet hose (5) to the radiator.
8. Install the hose clamp at the radiator inlet housing using the J 38185 .
9. Install the outlet heater hose (2).
10. Install the outlet heater hose clamp using the J 39529 .
11. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-197849-S08438024222005101300000) .
12. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-197835-S04559679502005101300000) in Engine Controls - 4.8L, 5.3L, 6.0L or «Air Cleaner Assembly Replacement»(ref-197838-S22629372012005101300000) in Engine Controls - 4.3L.
13. Inspect the automatic transmission fluid level. Refer to «Capacities - Approximate Fluid»(ref-197867-S33186411622005101300000) in General Information.
14. Inspect the engine oil level. Refer to «Capacities - Approximate Fluid»(ref-197867-S33186411622005101300000) in General Information.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Disconnect the heater cord from the coolant heater (4).
3. Loosen the coolant heater bolt.
4. Remove the coolant heater from the engine block.
5. Do not score the machined surface of the hole.
6. Grasp the plug with pliers.
7. Pull the plug from the engine block.
8. Clean the core plug hole in order to remove the following substances: Burrs Compound Paint Rough spots

1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 9985164 (Canadian P/N 10953480), or the equivalent.
2. Tightly push the coolant heater (1) into the engine block.
3. Tighten the coolant heater bolt until both of the locking wings draw tightly against the inner wall of the engine block. Tighten: Tighten the bolt to 2 N.m (18 lb in).
4. Connect the heater cord to the coolant heater (4).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
6. Inspect the cooling system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197837-S12044229642005101300000) in General Information.
3. Disconnect the coolant heater electrical connector (2).
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads.
2. Install the coolant heater to the engine block. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-197849-S29426166742005101300000) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-197837-S12044229642005101300000) in General Information.
2. Disconnect the coolant heater electrical connector (2).
3. Remove the coolant heater cord retainer and bolts.
4. Remove the coolant heater cord.

Note. The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.

1. Install the coolant heater cord.
2. Install the coolant heater cord bolts and retainer. Tighten: Tighten the coolant heater cord bolts to 8 N.m (71 lb in).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.