Engine Cooling System: Removal & Installation Chevrolet Silverado 1500 HD

Removal Procedure

Scheme 65

Scheme 66

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Reposition the inlet hose clamp at the radiator.
3. Remove the inlet hose from the radiator.
4. Reposition the inlet hose clamp at the water crossover.
5. Remove the inlet hose from the water crossover.

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Scheme 68

1. Install the inlet hose to the water crossover.
2. Position the inlet hose clamp at the water crossover.
3. Install the inlet hose to the radiator.
4. Position the inlet hose clamp at the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

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1. Separate the MAF/IAT sensor assembly and the air inlet tube by loosening the hose clamp.
2. Disconnect the PCV hose from the air cleaner outlet duct.
3. Remove the air inlet tube and resonator retaining wing nut.
4. Remove the air inlet tube and resonator from the throttle body by pivoting the air inlet tube and resonator upward until the hinge clip releases from the lip on the throttle body.
5. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
6. Remove the radiator outlet hose from the surge tank.
7. Remove the radiator outlet hose from the water pump.
8. Remove the radiator outlet hose from the radiator.
9. Remove the radiator outlet hose.

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1. Install the radiator outlet hose to the radiator.
2. Install the radiator outlet hose to the water pump.
3. Install the radiator outlet hose to the surge tank.
4. Align the hinge clip with the lip on the throttle body. Install the air inlet tube and resonator to the throttle body by pivoting the air inlet tube and resonator downward until the mounting stud is through the hole in the air inlet tube.
5. Install the resonator retaining wing nut.
6. Connect the PCV hose to the air cleaner outlet duct.
7. Connect the MAF/IAT sensor assembly harness connector.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

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1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass airflow/intake air temperature (MAF/IAT) sensor
3. Remove the radiator inlet hose clip from the outlet duct.
4. Remove the air cleaner outlet duct.
5. Reposition the outlet hose clamp at the water pump.
6. Remove the outlet hose from the water pump.
7. Reposition the outlet hose clamp at the radiator.
8. Remove the outlet hose from the radiator.

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1. Install the outlet hose to the radiator.
2. Position the outlet hose clamp at the radiator.
3. Install the outlet hose to the water pump.
4. Position the outlet hose clamp at the water pump. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud.
5. Install the air cleaner outlet duct.
6. Install the radiator inlet hose clip to the outlet duct.
7. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten Tighten the air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

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1. Drain the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Remove the upper and lower fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-188992-S11141372892005091300000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-188992-S15776187022005091300000) and «Fan Shroud Replacement - Lower»(ref-188992-S11200099902005091300000) .
3. Remove the surge tank outlet hose (2) from the surge tank.
4. Remove the radiator outlet hose from the water pump.
5. Remove the heater outlet hose from the radiator outlet hose.
6. Remove the radiator outlet hose from the radiator.
7. Remove the radiator outlet hose clip retainers from the brackets.
8. Remove the radiator outlet hose from the vehicle.

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Scheme 91

1. Install the radiator outlet hose to the vehicle.
2. Install the radiator outlet hose and clamp to the radiator. Ensure the hose is positioned properly in order to prevent interference with the fan shroud.
3. Install the radiator outlet hose clip retainers to the brackets.
4. Install the surge tank outlet hose (2) to the surge tank.
5. Install the radiator outlet hose and clamp to the water pump.
6. Install the heater outlet hose to the radiator outlet hose.
7. Install the upper and lower fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-188992-S11141372892005091300000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-188992-S15776187022005091300000) and «Fan Shroud Replacement - Lower»(ref-188992-S11200099902005091300000) .
8. Fill the engine coolant. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

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Scheme 94

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Reposition the outlet hose clamp at the radiator.
3. Remove the radiator outlet hose from the radiator.
4. Reposition the surge tank outlet hose clamp at the surge tank.
5. Remove the surge tank outlet hose (2) from the surge tank.
6. Reposition the outlet hose clamp the water pump.
7. Remove the outlet hose from the water pump.

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Scheme 97

1. Install the outlet hose from the water pump.
2. Position the outlet hose clamp the water pump.
3. Install the surge tank outlet hose (2) from the surge tank.
4. Position the surge tank outlet hose clamp at the surge tank.
5. Install the radiator outlet hose to the radiator.
6. Position the outlet hose clamp at the radiator.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 98

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Reposition the vent inlet hose clamp from the radiator.
3. Remove the vent inlet hose from the radiator.
4. Reposition the vent inlet hose clamp from the surge tank.
5. Remove the vent inlet hose from the surge tank.

Scheme 99

1. Install the vent inlet hose to the surge tank.
2. Reposition the vent inlet hose clamp to the surge tank.
3. Install the vent inlet hose to the radiator.
4. Reposition the vent inlet hose clamp to the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 100

Scheme 101

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.

Installation Procedure

Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting.

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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. IMPORTANT: Do not manually depress the retaining clip when installing the plastic cap.
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.

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Scheme 112

1. Remove the oil cooler lines from the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-188992-S15645450752005091300000) .
2. Open the oil cooler hose clip located on the lower fan shroud.
3. Remove the oil cooler hoses from the clip.
4. Raise and suitably support the vehicle. Refer to «JACKING AND LIFTING»(ref-188958) .
5. If equipped, remove the engine shield bolts.
6. Remove the engine shield.
7. If equipped with the a 6.0L engine, perform the following: 7.1. Remove the oil cooler hose bracket bolt (1). 7.2. Remove the oil cooler hose adapter bolts (2). 7.3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 7.4. Inspect the fittings, connectors and cooler hoses for damage or distortion.
8. If equipped with a 8.1L engine, perform the following: 8.1. Remove the oil cooler hose bracket bolt. 8.2. Disconnect the quick connect fittings (1) at the engine. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-188992-S15645450752005091300000) . 8.3. Remove the oil cooler hose assembly. 8.4. Inspect the fittings, connectors and cooler hoses for damage or distortion.

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Scheme 116

1. Install the oil cooler hose assembly.
2. If equipped with a 8.1L engine, perform the following: 2.1. Connect the quick connect fittings (1) at the engine. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-188992-S15645450752005091300000) . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . 2.2. Install the oil cooler hose bracket bolt. Tighten Tighten the bolt to 50 N.m (37 lb ft).
3. If equipped with a 6.0L engine, perform the following: 3.1. Install the oil cooler hose assembly and a new gasket. 3.2. Install the oil cooler hose adapter bolts (2). Tighten Tighten the bolts to 12 N.m (106 lb in). 3.3. Install the oil cooler hose bracket bolt (1). Tighten Tighten the bolt to 25 N.m (18 lb ft).
4. If equipped, install the engine shield.
5. Install the engine shield bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft).
6. Install the oil cooler hoses to the hose clip on the fan shroud.
7. Snap the oil cooler hose clip shut.

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Scheme 119

1. Install the fan clutch onto the fan blade. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the fan clutch bolts Tighten Tighten the bolts to 23 N.m (17 lb ft).
3. Install the fan assembly.
4. Install the J 46406 to the fan clutch. Tighten Tighten the nut clockwise to 56 N.m (41 lb ft).
5. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-188992-S11141372892005091300000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-188992-S15776187022005091300000) .

Note. Refer to FASTENER NOTICE .

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Scheme 122

1. Install the turbocharger bypass valve and washer. Tighten Tighten the valve to 60 N.m (44 lb ft).
2. Connect the turbocharger coolant return hose to the turbocharger bypass valve.
3. Install the upper intake manifold sight shield.
4. Install the upper intake manifold cover to the outlet duct.
5. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten Tighten the clamp to 6 N.m (53 lb in).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 123

1. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (4.3L Engine)»(ref-188992-S09523573242005091300000) or «Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.0L Engines)»(ref-188992-S18509211202005091300000) or «Radiator Hose Replacement - Outlet (6.6L Engine)»(ref-188992-S39871616312005091300000) or «Radiator Hose Replacement - Outlet (8.1L Engine)»(ref-188992-S41825676392005091300000) .
2. Remove the water pump inlet bolts.
3. Remove the water pump inlet and thermostat from the water pump.

Scheme 124

1. Install the thermostat and thermostat housing to the water pump. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the thermostat housing bolts. Tighten Tighten the bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (4.3L Engine)»(ref-188992-S09523573242005091300000) or «Radiator Hose Replacement - Outlet (4.8L, 5.3L, and 6.0L Engines)»(ref-188992-S18509211202005091300000) or «Radiator Hose Replacement - Outlet (6.6L Engine)»(ref-188992-S39871616312005091300000) or «Radiator Hose Replacement - Outlet (8.1L Engine)»(ref-188992-S41825676392005091300000) .

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Scheme 132

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Loosen the air cleaner outlet duct clamp at the mass airflow/intake air temperature (MAF/IAT) sensor.
3. Remove the positive crankcase ventilation (PCV) hose.
4. Remove the air cleaner adapter nut.
5. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body.
6. Reposition the inlet hose clamp at the water outlet.
7. Remove the inlet hose from the water outlet.
8. Remove the water outlet studs.
9. Remove the water outlet.
10. Remove the thermostat.
11. Clean the sealing surface of the water outlet.
12. Clean the sealing surface of the intake manifold.
13. Remove and discard the O-ring seal.

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Scheme 140

1. Install a NEW O-ring seal to the thermostat.
2. Install the thermostat.
3. Install the water outlet. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
4. Install the water outlet studs. Tighten Tighten the studs to 25 N.m (18 lb ft).
5. Install the inlet hose to the water outlet.
6. Position the inlet hose clamp at the water outlet.
7. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
8. Install the air cleaner adapter nut.
9. Install the PCV hose.
10. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
11. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
12. Inspect the cooling system for leaks.

Scheme 141

1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L Engine)»(ref-188992-S08051206432005091300000) .
2. Remove the bolt for the fuel line bracket.
3. Remove the thermostat housing cover bolts.
4. Remove the thermostats and seals.

Note. Refer to FASTENER NOTICE .

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1. If replacing the water crossover install the following: 1.1. Thermostat (3) 1.2. Water outlet (1) 1.3. Water outlet bolts (2) Tighten Tighten the bolts to 30 N.m (22 lb ft).
2. Install NEW water crossover gaskets.
3. Install the water crossover.
4. Install the water crossover bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft).
5. Install the generator bracket.
6. Install the generator bracket stud. Tighten Tighten the stud to 20 N.m (15 lb ft).
7. Install the generator bracket bolts and nut. Tighten Tighten the bolts and nut to 50 N.m (37 lb ft).
8. Install the power steering pump. Refer to «POWER STEERING PUMP REPLACEMENT (6.6 L DIESEL»(ref-188964-S41504307252005091100000) or «POWER STEERING PUMP REPLACEMENT (4.3 L)»(ref-188964-S18454437242005091100000) or «POWER STEERING PUMP REPLACEMENT (4.8L, 5.3L AND 6.0L)»(ref-188964-S01298919432005091100000) or «POWER STEERING PUMP REPLACEMENT (8.1L)»(ref-188964-S23129275222005091100000) .
9. Install the generator. Refer to «GENERATOR (4.3L ENGINE)»(ref-167946-S33213416432004102600000) or «GENERATOR (4.8L, 5.3L & 6.0L ENGINES)»(ref-167946-S15598882462004102600000) or «GENERATOR (6.6L ENGINE)»(ref-167946-S16823399902004102600000) or «GENERATOR (8.1L ENGINE)»(ref-167946-S20572431032004102600000) .
10. Install the bypass hose.
11. Position the bypass hose clamps at the water crossover and water pump.
12. Install the heater inlet hose to the water crossover.
13. Position the heater inlet hose clamp at the water crossover.
14. Install the inlet hose to the water crossover.
15. Position the inlet hose clamp at the water crossover.
16. Install the drive belt tensioner.
17. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

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Scheme 151

1. Remove the intake manifold. Refer to «INTAKE MANIFOLD»(ref-157348-S22774199032003081100000) .
2. Remove the coolant air bleed pipe bolts/studs (1).
3. Remove the coolant air bleed pipe (2) with gaskets (3).
4. Remove the coolant air bleed pipe cover bolts (1) and covers (2).
5. Remove the gaskets from the coolant air bleed pipe and covers.
6. Discard the gaskets.
7. Remove the coolant air bleed hose (1) from the pipe (2).

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Scheme 155

1. Install the coolant air bleed hose (1) onto the pipe (2). IMPORTANT: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe.
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. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
4. Install the coolant air bleed pipe bolts/studs (1). Tighten Tighten the bolts/studs to 12 N.m (106 lb in).
5. Install the coolant air bleed pipe covers (2) and bolts (1). Tighten Tighten the bolts to 12 N.m (106 lb in).
6. Install the intake manifold. Refer to «INTAKE MANIFOLD»(ref-157348-S22774199032003081100000) .

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Scheme 157

1. Reposition the coolant air bleed hose clamp at the throttle body.
2. Remove the coolant air bleed hose from the throttle body.
3. Reposition the coolant air bleed hose clamp at the pipe.
4. Remove the coolant air bleed hose (1) from the pipe (2).

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Scheme 159

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. Add engine coolant, if necessary.

Scheme 160

1. Remove the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-188992-S33452415332005091300000) .
2. Remove the thermostat bypass pipe and O-ring seal from the thermostat housing.
3. Remove and discard the O-ring seal.
4. Clean the sealing surfaces of the bypass pipe.
5. Clean the water pump and the thermostat housing crossover sealing surfaces.

Scheme 161

1. Install a new O-ring seal on the thermostat bypass pipe.
2. Lightly lubricate the O-ring seal with coolant.
3. Install a new O-ring seal for the bypass pipe to the water pump.
4. Install the bypass pipe in the thermostat housing.
5. Install the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-188992-S33452415332005091300000) .

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1. Install the water pump and NEW gaskets. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the water pump bolts. Tighten 2.1. Tighten the bolts a first pass to 15 N.m (11 lb ft). 2.2. Tighten the 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 surge tank outlet hose to the water pump.
6. Position the surge tank outlet hose clamp at the water pump.
7. Install the outlet hose to the water pump.
8. Position the outlet hose clamp at the water pump.
9. Install the accessory drive belt. Refer to «DRIVE BELT REPLACEMENT - ACCESSORY»(ref-188991-S29850027902005091300000) .
10. Install the fan blade. Refer to «Fan Replacement»(ref-188992-S38409126652005091300000) .
11. Install the inlet hose to the water pump.
12. Position the inlet hose clamp at the water pump.
13. Install the engine vent inlet hose to the radiator hose clips.
14. If necessary, install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, and 6.0L Engines)»(ref-188991-S42495646762005091300000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L ENGINE W/RPOS Y91 and Z88)»(ref-188991-S20954745852005091300000) . IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud.
15. Install the air cleaner outlet duct.
16. Install the radiator inlet hose clip to the outlet duct.
17. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten Tighten the clamps to 7 N.m (62 lb in).
18. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

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Scheme 170

1. Remove the left fender wheelhouse inner panel. Refer to «WHEELHOUSE PANEL REPLACEMENT»(ref-189023-S02109132082005091100000) .
2. Drain the engine coolant and the engine block. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
3. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-188992-S33452415332005091300000) .
4. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-188992-S34461718282005091300000) .
5. Remove the crankshaft balancer. Refer to «CRANKSHAFT BALANCER»(ref-161511-S01880688932004041300000) .
6. Remove the oil cooler inlet pipe to water pump nuts.
7. Remove the engine wiring harness retainer from the inner stud.
8. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths.
9. Remove the water pump.
10. Remove the water pump outlet pipe gasket.
11. If required, clean and inspect the water pump. Refer to «INSPECTION»(ref-161511-S11831720022004041300000) .

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Scheme 172

1. Lubricate the water pump O-ring with engine oil.
2. Install the water pump. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Tighten Tighten the bolts to 21 N.m (15 lb ft).
4. Install the water pump to oil cooler inlet pipe gasket.
5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud.
6. Install the water pump to oil cooler inlet pipe nuts. Tighten Tighten the nuts to 21 N.m (1 lb ft).
7. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-188992-S33452415332005091300000) .
8. Install the crankshaft balancer. Refer to «CRANKSHAFT BALANCER»(ref-161511-S01880688932004041300000) .
9. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-188992-S34461718282005091300000) .
10. Fill the engine with coolant. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
11. Install the left fender wheelhouse inner panel. Refer to «WHEELHOUSE PANEL REPLACEMENT»(ref-189023-S02109132082005091100000) .

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Scheme 175

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Remove the drive belt.
3. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-188992-S34461718282005091300000) .
4. Reposition the outlet hose clamp at the water pump.
5. Remove the outlet hose from the water pump.
6. Reposition the bypass hose clamps at the water pump and water crossover.
7. Remove the bypass hose.
8. Remove the water pump bolts.
9. Remove the water pump.
10. Remove and discard the water pump gaskets.

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Scheme 178

1. Place NEW water pump gaskets into place.
2. Install the water pump. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the water pump bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft).
4. Install the bypass hose.
5. Position the bypass hose clamps at the water pump and water crossover.
6. Install the outlet hose to the water pump.
7. Position the outlet hose clamp at the water pump.
8. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-188992-S34461718282005091300000) .
9. Install the drive belt.
10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 179

1. Remove the water pump. Refer to «Water Pump Replacement (4.3L Engine)»(ref-188992-S16947220012005091300000) or «Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-188992-S06384241062005091300000) or «Water Pump Replacement (6.6L Engine)»(ref-188992-S19697686162005091300000) or «Water Pump Replacement (8.1L Engine)»(ref-188992-S42173966292005091300000) .
2. Remove the oil cooler inlet/water pump outlet pipe from the engine oil cooler.
3. Remove and discard the O-ring seal.
4. Remove the gasket and clean the sealing surface.

Scheme 180

1. Install a new O-ring seal on the water pump outlet pipe.
2. Lightly lubricate the O-ring seal with engine oil.
3. Install the oil cooler inlet/water pump outlet pipe in the engine oil cooler.
4. Install a NEW oil cooler inlet pipe to water pump gasket.
5. Install the water pump. Refer to «Water Pump Replacement (4.3L Engine)»(ref-188992-S16947220012005091300000) or «Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-188992-S06384241062005091300000) or «Water Pump Replacement (6.6L Engine)»(ref-188992-S19697686162005091300000) or «Water Pump Replacement (8.1L Engine)»(ref-188992-S42173966292005091300000) .

Scheme 181

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Remove the radiator drain cock.

Scheme 182

1. Install the radiator drain cock.
2. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 183

Scheme 184

Scheme 185

1. Loosen the air cleaner outlet duct clamps from the throttle body.
2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
3. Remove the air cleaner outlet duct.
4. If equipped remove the throttle body heater hose retainer from the fan shroud.
5. If equipped remove the inlet radiator hose retainer from the fan shroud.
6. Remove the fan shroud retainers.
7. Remove the fan shroud bolts
8. Remove the upper fan shroud.

Scheme 186

Scheme 187

Scheme 188

1. Install the upper fan shroud. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the fan shroud bolts. Tighten Tighten the bolts to 9 N.m (80 lb in).
3. Install the fan shroud retainers.
4. If equipped install the inlet radiator hose retainer to the fan shroud
5. If equipped install the throttle body heater hose retainer to the fan shroud.
6. Install the air cleaner outlet duct.
7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten Tighten the clamp screw to 7 N.m (62 lb in).
8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten Tighten the clamp screw to 7 N.m (62 lb in).

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. Loosen the air cleaner outlet duct clamps from the throttle body.
2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
3. Remove the air cleaner outlet duct.
4. Remove the A/C line retainer from the fan shroud.
5. Remove the engine harness clip from the PCM cover.
6. Remove the TCM cover bolts.
7. Remove TCM cover from the fan shroud.
8. Loosen the TCM electrical connector bolts.
9. Disconnect the TCM electrical connectors (1).
10. Remove the TCM and cover.
11. Remove the fan shroud retainers.
12. Remove the fan shroud bolts
13. Remove the upper fan shroud.

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

1. Install the upper fan shroud. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the fan shroud bolts. Tighten Tighten the bolts to 9 N.m (80 lb in).
3. Install the fan shroud retainers.
4. Connect the TCM electrical connectors (1).
5. Install the TCM and cover.
6. Tighten the TCM electrical connector bolts. Tighten Tighten the bolts to 8 N.m (71 lb in).
7. Install the TCM cover to the fan shroud.
8. Install the TCM cover bolts. Tighten Tighten the bolts to 9 N.m (80 lb in).
9. Install the engine harness clip to the PCM cover.
10. Install the A/C line retainer to the fan shroud.
11. Install the air cleaner outlet duct.
12. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten Tighten the clamp screws to 7 N.m (62 lb in).
13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten Tighten the clamp screws to 7 N.m (62 lb in).

Scheme 201

1. Remove the cooling fan. Refer to «Fan Replacement»(ref-188992-S38409126652005091300000) .
2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud.
3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator.

Scheme 202

1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down.
2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud.
3. Install the cooling fan. Refer to «Fan Replacement»(ref-188992-S38409126652005091300000) .

Scheme 203

Scheme 204

Scheme 205

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Position the inlet hose clamp from the radiator.
3. Remove the inlet hose from the radiator.
4. Position the outlet hose clamp from the radiator.
5. Remove the radiator outlet hose from the radiator.
6. Remove the lower fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-188992-S11141372892005091300000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-188992-S15776187022005091300000) and «Fan Shroud Replacement - Lower»(ref-188992-S11200099902005091300000) .
7. Position the radiator vent inlet hose clamp from the radiator.
8. Remove the vent inlet hose from the radiator.
9. Remove the engine oil cooler lines from the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-188992-S15645450752005091300000) .
10. Remove the transmission oil cooler lines from the radiator. Refer to «TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING»(ref-188999-S13849205742005091400000) or «TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING»(ref-188998-S14130204822005091400000) .
11. Remove the radiator bolts.
12. Remove the radiator from the vehicle.

Scheme 206

Scheme 207

1. Install the radiator to the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the radiator bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
3. Install the engine oil cooler lines to the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-188992-S15645450752005091300000) .
4. Install the transmission oil cooler lines to the radiator. Refer to «TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING»(ref-188999-S13849205742005091400000) or «TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING»(ref-188998-S14130204822005091400000) .
5. Install the radiator vent inlet hose to the radiator.
6. Reposition the radiator vent inlet hose clamp to the radiator.
7. Install the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-188992-S11200099902005091300000) .
8. Install the outlet hose to the radiator.
9. Reposition the outlet hose clamp to the radiator.
10. Install the inlet hose to the radiator.
11. Reposition the inlet hose clamp to the radiator.
12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 208

1. Remove the radiator. Refer to «Radiator Replacement»(ref-188992-S41168071262005091300000) .
2. Remove the radiator air baffle retainers.
3. Remove the radiator air baffles.

Scheme 209

1. Install the radiator air baffles.
2. Install the radiator air baffle retainers.
3. Install the radiator. Refer to «Radiator Replacement»(ref-188992-S41168071262005091300000)

Scheme 210

1. Remove the radiator air upper baffle retainers.
2. Remove the radiator air upper baffle.

Scheme 211

1. Install the radiator air upper baffle.
2. Install the radiator air upper baffle retainers.

Scheme 212

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
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

Scheme 213

Scheme 214

Scheme 215

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. IMPORTANT: Avoid element contact with the inside walls of the engine block.
2. Tightly push the coolant heater (1) into the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
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). 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.
4. Connect the heater cord to the coolant heater (4).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
6. Inspect the cooling system for leaks.

Scheme 216

Scheme 217

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Raise and suitably support the vehicle. Refer to «JACKING AND LIFTING»(ref-188958) .
3. Disconnect the coolant heater electrical connector (2). IMPORTANT: Do not score the surface of the engine block hole when removing the coolant heater.
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

Scheme 218

Scheme 219

1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the coolant heater to the engine block. Tighten Tighten the coolant heater to 50 N.m (37 lb ft). 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.
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-188992-S10584397332005091300000) .

Scheme 220

Scheme 221

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Remove the right front tire and wheel. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-188972-S29728641722005091100000) .
3. Remove the right engine mount .
4. Disconnect the engine coolant heater cord.
5. Loosen the coolant heater bolt.
6. Remove the engine coolant heater from the engine block.
7. Do not score the machined surface of the hole.
8. Grasp the plug with pliers.
9. Pull the plug from the engine block.
10. Clean the core plug hole in order to remove the following substances: Burrs Compound Paint Rough spots

Scheme 222

Scheme 223

Scheme 224

1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 1052196 (Canadian P/N 5264008), or the equivalent. IMPORTANT: Avoid element contact with the inside walls of the engine block.
2. Align the coolant heater element to point towards the top of the engine.
3. Tightly push the coolant heater into the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
4. Tighten the bolt on the engine coolant heater 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). 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.
5. Connect the heater cord to the coolant heater.
6. Install the right engine mount.
7. Install the right front tire and wheel. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-188972-S29728641722005091100000) .
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
9. Inspect for coolant leaks.

Scheme 225

Scheme 226

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .
2. Disconnect the block heater cord from the block heater.
3. Remove the engine block heater.

Scheme 227

Scheme 228

1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the engine block heater. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the engine block heater into the block. Tighten Tighten the coolant heater to 60 N.m (40 lb ft). 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.
3. Connect the block heater cord to the block heater.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-188992-S10584397332005091300000) .

Scheme 229

Scheme 230

1. Raise and suitably support the vehicle. Refer to «JACKING AND LIFTING»(ref-188958) .
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.

Scheme 231

Scheme 232

1. Install the coolant heater cord. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the coolant heater cord bolts and retainer. Tighten Tighten the bolts to 8 N.m (71 lb in).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.