Home ReviewsRefund
Home/Chevrolet/Silverado Classic 3500/Chevrolet Silverado Classic 3500 (2007-2007)/Repair manual/Cooling System (Mechanical)/Engine Cooling System: Removal & Installation
Contents Wiring diagrams Section: Cooling System (Mechanical) All sections

Engine Cooling System: Removal & Installation Chevrolet Silverado Classic 3500

Cooling System (Mechanical) ~15782 words

Removal Procedure

  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-277873-S36739584182008012100000) for the 4.3 L engine, «Air Cleaner Assembly Replacement»(ref-277872-S13022439462008012100000) for the 4.8 L, 5.3 L, and 6.0 L engine or «Air Cleaner Assembly Replacement»(ref-277874-S19644157782008012100000) for the 8.1 L engine.
  3. Remove the surge tank overflow hose from the surge tank.
  4. Disconnect the coolant level sensor electrical connector (3).
  5. Reposition the surge tank inlet and outlet hose clamps.
  6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank.
  7. Reposition the surge tank inlet hose clamp from the surge tank.
  8. Remove the surge tank inlet hose (1) from the surge tank.
  9. Reposition the surge tank outlet hose clamp from the surge tank.
  10. Remove the surge tank outlet hose (2) from the surge tank.
  11. Remove the bolt from the surge tank.
  12. Remove the nut from the surge tank.
  13. Remove the surge tank.

Installation Procedure

  1. Install the surge tank.
  2. Install the bolt to the surge tank. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  3. Install the nut to the surge tank. Tighten: Tighten the nut to 9 N.m (80 lb in).
  4. Install the surge tank outlet hose (2) to the surge tank.
  5. Position the surge tank outlet hose clamp to the surge tank.
  6. Install the surge tank inlet hose (1) to the surge tank.
  7. Position the surge tank inlet hose clamp to the surge tank.
  8. Connect the coolant level sensor electrical connector (3).
  9. Install the surge tank overflow hose.
  10. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-277873-S36739584182008012100000) for the 4.3 L engine, «Air Cleaner Assembly Replacement»(ref-277872-S13022439462008012100000) for the 4.8 L, 5.3 L, and 6.0 L engine or «Air Cleaner Assembly Replacement»(ref-277874-S19644157782008012100000) for the 8.1 L engine.
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Reposition the surge tank inlet hose clamp from the radiator.
  3. Remove the surge tank inlet hose from the radiator.
  4. Reposition the surge tank inlet hose clamp from the surge tank.
  5. Remove the surge tank inlet hose (1) from the surge tank.
  1. Install the surge tank inlet hose (1) to the surge tank.
  2. Position the surge tank inlet hose clamp to the surge tank.
  3. Install the surge tank inlet hose to the radiator.
  4. Position the surge tank inlet hose clamp to the radiator.
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Separate the mass airflow (MAF)/intake air temperature (IAT) sensor assembly and the air inlet tube by loosening the hose clamp.
  3. Disconnect the positive crankcase ventilation (PCV) hose from the air cleaner outlet duct.
  4. Remove the air inlet tube and resonator retaining wing nut.
  5. 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.
  6. Reposition the radiator inlet hose clamp.
  7. Remove the radiator inlet hose from the radiator.
  8. Reposition the radiator inlet hose clamp at the thermostat housing.
  9. Remove the radiator inlet hose from the thermostat housing.
  10. Remove the radiator inlet hose.
  1. Install the radiator inlet hose to the radiator.
  2. Reposition the radiator inlet hose clamp at the radiator.
  3. Install the radiator inlet hose to the thermostat housing.
  4. Reposition the radiator inlet hose clamp at the thermostat housing.
  5. Place the radiator inlet hose onto the support.
  6. 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.
  7. Install the resonator retaining wing nut.
  8. Connect the PCV hose to the air cleaner outlet duct.
  9. Install the MAF/IAT sensor assembly and the air inlet duct. Tighten: Tighten the clamps to 4 N.m (35 lb in).
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 hose.
  4. Remove the air cleaner outlet duct.
  5. If necessary, remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(ref-277904-S40900535922008012100000) or «Upper Intake Manifold Sight Shield Replacement (6.0L (RPO LQ9))»(ref-277904-S18400695242008012100000) .
  6. Remove the radiator vent inlet hose from the radiator inlet hose clips.
  7. Reposition the inlet hose clamp at the radiator.
  8. Remove the inlet hose clip from the fan shroud.
  9. Remove the inlet hose (1) from the radiator.
  10. Reposition the inlet hose clamp at the water pump.
  11. Remove the inlet hose from the water pump.
  1. Install the inlet hose to the water pump.
  2. Position the inlet hose clamp at the water pump.
  3. Install the inlet hose (1) to the radiator.
  4. Position the inlet hose clamp at the radiator.
  5. Install the inlet hose clip to the fan shroud.
  6. Install the radiator vent inlet hose to the radiator inlet hose clips.
  7. If necessary, install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(ref-277904-S40900535922008012100000) or «Upper Intake Manifold Sight Shield Replacement (6.0L (RPO LQ9))»(ref-277904-S18400695242008012100000) .
  8. Install the air cleaner outlet duct.
  9. Install the radiator inlet hose clip to the outlet duct.
  10. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the clamps to 4 N.m (35 lb in).
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 hose.
  4. Remove the air cleaner outlet duct.
  5. If necessary, remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(ref-277904-S40900535922008012100000) or «Upper Intake Manifold Sight Shield Replacement (6.0L (RPO LQ9))»(ref-277904-S18400695242008012100000) .
  6. Remove the radiator vent inlet hose from the radiator inlet hose clips.
  7. Reposition the inlet hose clamp at the radiator.
  8. Remove the inlet hose clip from the fan shroud.
  9. Remove the inlet hose from the radiator.
  10. Reposition the inlet hose clamp at the water pump.
  11. Remove the inlet hose from the water pump.
  1. Install the inlet hose to the water pump.
  2. Position the inlet hose clamp at the water pump.
  3. Install the inlet hose to the radiator.
  4. Position the inlet hose clamp at the radiator.
  5. Install the inlet hose clip to the fan shroud.
  6. Install the radiator vent inlet hose to the radiator inlet hose clips.
  7. If necessary, install the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(ref-277904-S40900535922008012100000) or «Upper Intake Manifold Sight Shield Replacement (6.0L (RPO LQ9))»(ref-277904-S18400695242008012100000) .
  8. Install the air cleaner outlet duct.
  9. Install the radiator inlet hose clip to the outlet duct.
  10. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the clamps to 6 N.m (35 lb in).
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Move the hose clamps back on the radiator inlet hose.
  3. Remove the radiator inlet hose from the radiator.
  4. Remove the radiator inlet hose from the water outlet tube.
  1. Install the radiator inlet hose to the water outlet tube.
  2. Install the radiator inlet hose to the radiator.
  3. Install the hose clamps on the radiator outlet hose.
  4. Fill the engine coolant. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
IMPORTANTMost truck models use a spring-type hose clamp at the hose connections. When using this type of clamp, install the radiator hoses on dry, non-painted surfaces in order to ensure proper sealing. Reusing the spring-type clamps on aftermarket hoses is not recommended.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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.
  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 (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Separate the mass airflow (MAF)/intake air temperature (IAT) sensor assembly and the air inlet tube by loosening the hose clamp.
  2. Disconnect the positive crankcase ventilation (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 (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 radiator outlet hose clamp at the radiator.
  10. Remove the radiator outlet hose from the radiator.
  11. Remove the radiator outlet hose.
  1. Install the radiator outlet hose to the radiator.
  2. Reposition the radiator outlet hose clamp at the radiator.
  3. Install the radiator outlet hose to the water pump.
  4. Install the radiator outlet hose to the surge tank.
  5. Reposition the radiator outlet hose clamps at the surge tank and water pump.
  6. 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.
  7. Install the resonator retaining wing nut.
  8. Connect the PCV hose to the air cleaner outlet duct.
  9. Install the MAF/IAT sensor assembly and the air inlet duct. Tighten: Tighten the clamps to 4 N.m (35 lb in).
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 (6) from the radiator.
  1. Install the outlet hose (6) 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.
  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 clamps to 4 N.m (35 lb in).
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass air flow (MAF)/intake air temperature (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 from the water pump.
  6. Remove the outlet hose from the water pump.
  7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  8. Remove the bolts from the engine shield.
  9. Remove the engine shield from the vehicle.
  10. Reposition the radiator outlet hose clamp (2) from the starter/generator stator cooler inlet pipe (3).
  11. Remove the radiator outlet hose (1) from the starter/generator stator cooler inlet pipe (3).
  12. Reposition the outlet hose clamp from the radiator.
  13. Remove the outlet hose from the radiator.
  1. Install the outlet hose to the radiator.
  2. Position the outlet hose clamp to the radiator.
  3. Install the radiator outlet hose (1) to the starter/generator stator cooler inlet pipe (3).
  4. Position the radiator outlet hose clamp (2) to the starter/generator stator cooler inlet pipe (3).
  5. Install the engine shield to the vehicle.
  6. Install the bolts to the engine shield. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  7. Lower the vehicle.
  8. Install the outlet hose to the water pump.
  9. Position the outlet hose clamp to the water pump.
  10. Install the air cleaner outlet duct.
  11. Install the radiator inlet hose clip to the outlet duct.
  12. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the clamps to 4 N.m (35 lb in).
  13. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Remove the upper and lower fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) and «Engine Coolant Fan Lower Shroud Replacement»(ref-277850-S42558773622008012100000) .
  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.
  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 «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) and «Engine Coolant Fan Lower Shroud Replacement»(ref-277850-S42558773622008012100000) .
  8. Fill the engine coolant. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
IMPORTANTMost truck models use a spring-type hose clamp at the hose connections. When using this type of clamp, install the radiator hoses on dry, non-painted surfaces in order to ensure proper sealing. Reusing the spring-type clamps on aftermarket hoses is not recommended.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Remove the radiator outlet hose from the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-277850-S24917051732008012100000) .
  3. Using the J 43181 disconnect the heater hoses from the heater core outlet. See «Special Tools»(ref-277850-S19943780362008012100000) . Install the J 43181 to the heater core pipe. See «Special Tools»(ref-277850-S19943780362008012100000) . Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  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.
  1. Install the outlet hose to the water pump.
  2. Position the outlet hose clamp to the water pump.
  3. Install the surge tank outlet hose (2) from the surge tank.
  4. Position the surge tank outlet hose clamp to the surge tank.
  5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
  6. Install the radiator outlet hose to the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-277850-S24917051732008012100000) .
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. 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.
  2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed.
  3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1).
  1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector.
  2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
  3. 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.
  4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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.
  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 (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  2. If equipped with a 5.3L or 6.0L engine, perform the following: Open the oil cooler hose clip located on the lower fan shroud. Remove the oil cooler hoses from the clip.
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  4. If equipped with a 8.1L engine, perform the following
  5. Remove the oil cooler hoses from the clip.
  6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  7. If equipped, remove the engine shield bolts.
  8. Remove the engine shield.
  9. If equipped with a 5.3L or 6.0L engine, perform the following: Remove the oil cooler hose bracket bolt (1). Remove the oil cooler hose adapter bolts (2). Remove the oil cooler hose assembly and gasket. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
  10. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hose bracket bolt. Disconnect the quick connect fittings (1) at the engine. Remove the oil cooler hose assembly. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
  1. If equipped with a 8.1L engine, perform the following: Install the oil cooler hose assembly and a NEW gasket. Connect the quick connect fittings (1) at the engine. NOTE: Refer to «Fastener Notice»(ref-277849-S30907907212008012100000) . Install the oil cooler hose bracket bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  2. If equipped with a 5.3L or 6.0L engine, perform the following: Install the oil cooler hose assembly and a NEW gasket. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the bolts to 12 N.m (106 lb in). Install the oil cooler hose bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  3. If equipped, install the engine shield.
  4. Install the engine shield bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  5. Lower the vehicle.
  6. If equipped with a 5.3L or 6.0L engine, perform the following: Install the oil cooler hoses to the hose clip on the fan shroud. Snap the oil cooler hose clip shut.
  7. If equipped with a 8.1L engine perform the following
  8. Install the oil cooler hoses to the clip.
  9. Connect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .

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 engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  2. If equipped with a 5.3L or 6.0L engine, perform the following: Open the oil cooler hose clip located on the lower fan shroud. Remove the oil cooler hoses from the clip.
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  4. If equipped with a 8.1L engine, perform the following
  5. Remove the oil cooler hoses from the clip.
  6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  7. Place jack or utility stands at the rear of the vehicle.
  8. If equipped, remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-277879-S31943219262008012100000) .
  9. If equipped, remove the front differential carrier shield. Refer to «Shield Replacement»(ref-277880-S16352542082008012100000) .
  10. Place an adjustable jack under the front differential carrier.
  11. Remove the inner axle housing nuts and washers from the bracket.
  12. Remove the differential carrier upper mounting bolt and nut.
  13. Pivot the differential carrier forward and down on the lower mount bolt while it is being supported by the adjustable jack.
  14. Secure the differential carrier to the jack.
  15. Remove the differential carrier lower mounting bolt and nut.
  16. Lower the jack 4 to 6 inches.
  17. If equipped with a 5.3L or 6.0L engine, perform the following: Remove the oil cooler hose bracket bolt (1). Remove the oil cooler hose adapter bolts (2). Remove the oil cooler hose assembly and gasket. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
  18. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hose bracket bolt. Disconnect the quick connect fittings (1) at the engine. Remove the oil cooler hose assembly. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
  1. If equipped with a 8.1L engine, perform the following: Install the oil cooler hose assembly and a NEW gasket. Connect the quick connect fittings (1) at the engine. Install the oil cooler hose bracket bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  2. If equipped with a 5.3L or 6.0L engine, perform the following: Install the oil cooler hose assembly and a NEW gasket. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the bolts to 12 N.m (106 lb in). Install the oil cooler hose bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  3. Raise the jack in order to position the differential carrier.
  4. Install the differential carrier lower mounting bolt and nut. Do not tighten the bolt at this time.
  5. Pivot the differential carrier up and back on the lower mount bolt while it is being supported by the jack.
  6. Install the differential carrier upper mounting bolt and nut. Do not tighten the bolt at this time.
  7. Install the inner axle housing washers and nuts to the brackets. Tighten: The inner axle housing bolts to 100 N.m (75 lb ft). The upper and lower differential carrier bolts to 100 N.m (75 lb ft).
  8. Remove the adjustable jack from under the front differential carrier.
  9. If equipped, install the front differential carrier shield. Refer to «Shield Replacement»(ref-277880-S16352542082008012100000) .
  10. If equipped, install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-277879-S31943219262008012100000) .
  11. Remove the jack or utility stands from the rear of the vehicle.
  12. Lower the vehicle.
  13. If equipped with a 8.1L engine perform the following
  14. Install the oil cooler hoses to the clip.
  15. If equipped with a 5.3L or 6.0L engine, perform the following: Install the oil cooler hoses to the hose clip on the fan shroud. Snap the oil cooler hose clip shut.
  16. Connect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  2. Remove the 3 engine cooling fan shroud bolts (1).
  3. Position the engine cooling fan shroud (1) forward to the radiator.
  4. Install a long pin bar into the fan hub (1).
  5. Use a J 41240-5A to remove the fan hub nut (2) from the hub in a counterclockwise rotation.
  6. Remove the fan and the engine cooling fan shroud as an assembly.
  7. Remove the fan clutch bolts from the rear of the fan blade.
  8. Separate the fan clutch from the fan blade.
CAUTIONDo not use or attempt to repair a damaged cooling fan assembly. Replace damaged fans with new assemblies. An unbalanced cooling fan could fly apart causing personal injury and property damage.
  1. Install the fan clutch onto the fan blade.
  2. Install the fan clutch bolts Tighten: Tighten the bolts to 23 N.m (17 lb ft).
  3. Install the fan and engine cooling fan shroud assembly to the fan hub.
  4. Use a J 41240-5A on the fan clutch hub nut (2) to install a long pry bar to the fan clutch hub (1). Tighten: Tighten the nut clockwise to 56 N.m (41 lb ft).
  5. Position the engine cooling fan shroud on the 3 mounting brackets (1).
  6. Install the bolts. Loosely tighten the top mounting bolt at the oil filler neck.
  7. Center the engine cooling fan shroud to the fan blade in 3 places (1).
  8. Fully tighten the 3 engine cooling fan shroud bolts (1). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  9. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  2. Install the J 46406 to the fan clutch. See «Special Tools»(ref-277850-S19943780362008012100000) .
  3. Remove the fan hub nut from the water pump in a counterclockwise rotation.
  4. Remove the fan clutch bolts from the rear of the fan blade.
  5. Separate the fan clutch from the fan blade.
CAUTIONDo not use or attempt to repair a damaged cooling fan assembly. Replace damaged fans with new assemblies. An unbalanced cooling fan could fly apart causing personal injury and property damage.
  1. Install the fan clutch onto the fan blade.
  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. See «Special Tools»(ref-277850-S19943780362008012100000) . Tighten: Tighten the nut clockwise to 56 N.m (41 lb ft).
  5. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  2. Remove the 3 engine cooling fan shroud bolts (1).
  3. Position the engine cooling fan shroud (1) forward to the radiator.
  4. Install a long pin bar into the fan hub (1).
  5. Use a J 41240-5A to remove the fan hub nut (2) from the hub in a counterclockwise rotation.
  6. Remove the fan and the engine cooling fan shroud as an assembly.
  7. Remove the fan clutch bolts from the rear of the fan blade.
  8. Separate the fan clutch from the fan blade.
CAUTIONDo not use or attempt to repair a damaged cooling fan assembly. Replace damaged fans with new assemblies. An unbalanced cooling fan could fly apart causing personal injury and property damage.
  1. Install the fan clutch onto the fan blade.
  2. Install the fan clutch bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
  3. Install the fan and engine cooling fan shroud assembly to the fan hub.
  4. Use a J 41240-5A on the fan clutch hub nut (2) to install a long pry bar to the fan clutch hub (1). Tighten: Tighten the nut clockwise to 56 N.m (41 lb ft).
  5. Position the engine cooling fan shroud on the 3 mounting brackets (1).
  6. Install the bolts. Loosely tighten the top mounting bolt at the oil filler neck.
  7. Center the engine cooling fan shroud to the fan blade in 3 places (1).
  8. Fully tighten the 3 engine cooling fan shroud bolts (1). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  9. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  2. Install the J 46406 to the fan clutch. See «Special Tools»(ref-277850-S19943780362008012100000) .
  3. Remove the fan hub nut from the water pump in a counterclockwise rotation.
  4. Remove the fan clutch bolts from the rear of the fan blade.
  5. Separate the fan clutch from the fan blade.
  1. Install the fan clutch bolts from the rear of the fan blade.
  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. See «Special Tools»(ref-277850-S19943780362008012100000) . Tighten: Tighten the nut clockwise to 56 N.m (41 lb ft).
  5. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  1. Remove the fan clutch. Refer to «Fan Clutch Replacement (Diesel)»(ref-277850-S37736304992008012100000) or «Fan Clutch Replacement (Gasoline)»(ref-277850-S11335759712008012100000) .
  2. Disconnect the camshaft position (CMP) sensor electrical connector.
  3. Remove the fan pulley bolts/nuts.
  4. Remove the fan pulley.
  1. Install the fan pulley.
  2. Install the fan pulley bolts/nuts. Tighten: Tighten the bolts/nuts to 41 N.m (30 lb ft).
  3. Connect the CMP sensor electrical connector (1).
  4. Install the fan clutch. Refer to «Fan Clutch Replacement (Diesel)»(ref-277850-S37736304992008012100000) or «Fan Clutch Replacement (Gasoline)»(ref-277850-S11335759712008012100000) .
  1. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-277850-S20590404252008012100000) .
  2. Remove the cooling fan blade retainers.
  3. Remove the cooling fan blades.
IMPORTANTThe electric cooling fan assembly uses a 5-blade fan and a 7-blade fan, it does not matter which side the fan blades are installed on. DO NOT install two 5-blade assemblies or two 7-blade assemblies, as this would cause a noise issue.
  1. Install the cooling fan blades.
  2. Install the cooling fan blade retainers.
  3. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-277850-S20590404252008012100000) .
  1. Remove the cooling blade(s). Refer to «Engine Cooling Fan Replacement»(ref-277850-S40874301422008012100000) .
  2. Remove the cooling fan motor bolts.
  3. Remove the cooling fan motor(s).
  1. Install the cooling fan motor(s).
  2. Install the cooling fan motor bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the cooling fan blade(s). Refer to «Engine Cooling Fan Replacement»(ref-277850-S40874301422008012100000) .
  1. Disengage the radiator inlet hose clip (2) at the fan shroud.
  2. Reposition the surge tank inlet hose clamp at the radiator.
  3. Remove the surge tank inlet hose from the radiator.
  4. Disconnect the electrical connectors from the cooling fans.
  5. Remove the clip attaching the wiring harness to the shroud.
  6. If necessary, open the engine oil cooler line clip and remove the cooler lines from the clip.
  7. Remove the cooling fan shroud bolts.
  8. Remove the cooling fan and shroud.
  1. Install the cooling fan and shroud.
  2. Install the cooling fan shroud bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  3. If equipped, install the cooler lines to the clip and close the clip.
  4. Connect the electrical connectors to the cooling fans.
  5. Install the clip attaching the wiring harness to the shroud.
  6. Install the surge tank inlet hose to the radiator.
  7. Reposition the surge tank inlet hose clamp at the radiator.
  8. Engage the radiator inlet hose clip (2) at the fan shroud.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. Reposition the coolant inlet hose clamp.
  4. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.
  5. Remove the turbocharger bypass valve and washer.
  1. Install the turbocharger bypass valve and washer. Tighten: Tighten the valve to 60 N.m (44 lb ft).
  2. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.
  3. Position the coolant inlet hose clamp.
  4. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
  4. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
  5. Reposition the turbocharger coolant inlet hose clamp at the bypass valve.
  6. Remove the turbocharger coolant inlet hose banjo bolt (1).
  7. Remove the inlet hose washer and inlet line.
  1. Install the inlet hose washer and inlet line.
  2. Install the turbocharger coolant inlet hose banjo bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  3. Position the turbocharger coolant inlet hose clamp at the bypass valve.
  4. Remove the tape from the turbocharger openings.
  5. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  6. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnection and Connection (Auxiliary Battery)»(ref-277854-S37314824542008012100000) or «Battery Negative Cable Disconnection and Connection (Single Battery)»(ref-277854-S29426527292008012100000) .
  4. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-277871-S00762267862008012100000) .
  5. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  6. Remove the charged air cooler duct from the intake.
  7. Remove the generator mounting bracket. Refer to «Generator Bracket Replacement (4.3L Engine)»(ref-277854-S25339034002008012100000) or «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-277854-S29267388952008012100000) or «Generator Bracket Replacement (6.6L Engine)»(ref-277854-S19591817802008012100000) or «Generator Bracket Replacement (8.1L Engine)»(ref-277854-S13092536382008012100000) .
  8. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(ref-277871-S20280986472008012100000) .
  9. Reposition the hose clamp at the bypass pipe.
  10. Remove the turbocharger coolant outlet hose from the bypass pipe.
  11. Reposition the turbocharger coolant outlet hose clamp.
  12. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.
  13. Remove the turbocharger coolant outlet pipe bolt and nut.
  14. If necessary, remove the turbocharger. Refer to «Turbocharger Replacement (RPOs LBZ/LLY)»(ref-277954-S02996140812008012100000) .
  15. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
  16. If necessary, remove the coolant outlet pipe.
  1. If necessary, install the coolant outlet pipe.
  2. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  3. If necessary, install the turbocharger. Refer to «Turbocharger Replacement (RPOs LBZ/LLY)»(ref-277954-S02996140812008012100000) .
  4. Install the turbocharger coolant outlet pipe bolt and nut. Tighten: Tighten the bolt/nut to 9 N.m (80 lb in).
  5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
  6. Position the turbocharger coolant outlet hose clamp.
  7. Install the turbocharger coolant outlet hose to the bypass pipe.
  8. Position the hose clamp at the bypass pipe.
  9. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(ref-277871-S20280986472008012100000) .
  10. Install the generator mounting bracket. Refer to «Generator Bracket Replacement (4.3L Engine)»(ref-277854-S25339034002008012100000) or «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-277854-S29267388952008012100000) or «Generator Bracket Replacement (6.6L Engine)»(ref-277854-S19591817802008012100000) or «Generator Bracket Replacement (8.1L Engine)»(ref-277854-S13092536382008012100000) .
  11. Install a NEW quick connect fitting clip to the charged air cooler duct.
  12. Install the charged air cooler duct to the intake.
  13. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-277871-S00762267862008012100000) .
  14. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnection and Connection (Auxiliary Battery)»(ref-277854-S37314824542008012100000) or «Battery Negative Cable Disconnection and Connection (Single Battery)»(ref-277854-S29426527292008012100000) .
  15. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  16. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-277871-S00762267862008012100000) .
  3. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  4. Remove the charged air cooler outlet duct from the intake.
  5. Remove the electrical harness bolts.
  6. Reposition the engine harness from the air inlet tube.
  7. Remove the air inlet tube to intake manifold tube bolt and nut.
  8. Disconnect the air intake heater electrical connector.
  9. Disconnect manifold absolute pressure (MAP) sensor electrical connector.
  10. Remove the engine harness clip from the air inlet tube.
  11. Remove the air inlet tube nuts.
  12. Remove the air inlet tube.
  13. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  14. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp.
  15. Remove the EGR coolant pipe hose.
  16. Remove the EGR coolant pipe bolts.
  17. Remove the EGR coolant pipe.
  18. Remove and discard the coolant pipe O-ring seal.
  1. Install a NEW O-ring seal onto the coolant pipe. Lubricate the seal with engine coolant.
  2. Install the EGR coolant pipe.
  3. Install the EGR coolant pipe bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  4. Install the EGR coolant pipe hose.
  5. Position the EGR coolant pipe hose clamp.
  6. Connect the ECT sensor electrical connector.
  7. Install the air inlet tube.
  8. Install the air inlet tube nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  9. Connect the air intake heater electrical connector.
  10. Connect MAP sensor electrical connector.
  11. Install the engine harness clip to the air inlet tube.
  12. Install the air inlet tube to intake manifold tube bolt and nut. Tighten: Tighten the bolt/nut to 10 N.m (89 lb in).
  13. Position the engine harness to the air inlet tube.
  14. Install the engine harness bolts. Tighten: Tighten the bolts to 4 N.m (35 lb in).
  15. Install a NEW quick connect fitting clip to the charged air cooler duct.
  16. Install the charged air cooler outlet duct to the intake.
  17. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-277871-S00762267862008012100000) .
  18. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  2. Drain the cooling system and engine block. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. If necessary, disconnect the crankshaft position (CKP) sensor electrical connector.
  4. Remove the thermal bypass hose bolt.
  5. Reposition the thermal bypass hose clamp.
  6. Remove the thermal bypass hose from the fitting.
  7. Remove the thermal bypass fitting.

Note. Refer to Fastener Notice .

IMPORTANTCheck that the coolant hose sealing surfaces are clean and not damaged. Confirm that the hose clamp retention is adequate and the coolant hose is not deformed. Damaged components must be replaced to avoid coolant leaks.
  1. Install the thermal bypass fitting. Tighten: Tighten the fitting to 35 N.m (26 lb ft).
  2. Install the thermal bypass hose to the fitting.
  3. Position the thermal bypass hose clamp.
  4. Install the thermal bypass hose bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. If necessary, connect the CKP sensor electrical connector.
  6. Fill the cooling system and engine block. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  7. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  2. Drain the cooling system and engine block. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. If necessary, disconnect the crankshaft position (CKP) sensor electrical connector.
  4. Remove the thermal bypass hose bolt.
  5. Reposition the thermal bypass hose clamp.
  6. Remove the thermal bypass hose from the fitting.
IMPORTANTCheck that the coolant hose sealing surfaces are clean and not damaged. Confirm that the hose clamp retention is adequate and the coolant hose is not deformed. Damaged components must be replaced to avoid coolant leaks.
  1. Install the thermal bypass hose to the fitting.
  2. Position the thermal bypass hose clamp. NOTE: Refer to «Fastener Notice»(ref-277849-S30907907212008012100000) .
  3. Install the thermal bypass hose bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  4. If necessary, connect the CKP sensor electrical connector.
  5. Fill the cooling system and engine block. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  6. Lower the vehicle.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. Remove the radiator inlet hose from the water outlet tube.
  4. Open the clip and remove the wiring harness branch from the bracket.
  5. Remove the bolt and wiring harness bracket at the thermostat housing.
  6. Remove the main engine electrical harness connector bolts.
  7. Disconnect the turbocharger vane position sensor electrical connector.
  8. Remove the main electrical harness bracket bolts.
  9. Remove the main electrical harness bracket.
  10. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.
  11. Remove the water outlet bolts.
  12. Remove the water outlet.
  13. Remove and discard the O-ring seal.
  1. Install a NEW O-ring seal to the water outlet.
  2. Lubricate the O-ring seal with clean engine coolant.
  3. Install the water outlet.
  4. Install the water outlet bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  5. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.
  6. Install the main electrical harness bracket.
  7. Install the main electrical harness bracket bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  8. Connect the turbocharger vane position sensor electrical connector.
  9. Install the main engine electrical harness connector bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  10. Install the wiring harness bracket and bolt to the thermostat housing. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  11. Install the wiring harness branch to the bracket and close the clip.
  12. Install the radiator inlet hose to the water outlet tube.
  13. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
IMPORTANTThe thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly.
  1. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  2. Remove the water pump inlet bolts.
  3. Remove the water pump inlet and thermostat from the water pump.
  1. Install the thermostat and thermostat housing to the water pump.
  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 Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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.
  1. Install a NEW O-ring seal to the thermostat.
  2. Install the thermostat.
  3. Install the water outlet.
  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. Tighten: Tighten the clamps to 4 N.m (35 lb in).
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  12. Inspect the cooling system for leaks.
  1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L Engine)»(ref-277850-S28537429092008012100000) .
  2. Remove the bolt for the fuel line bracket.
  3. Remove the fuel line bracket.
  4. Remove the thermostat housing cover bolts.
  5. Remove the thermostat housing cover.
  6. Remove the thermostats and seals.
  1. Install the thermostats and seals to the thermostat housing. The rear thermostat (4) has 2 vent valves. Install with the vent valves towards the rear of engine.
  2. Install the thermostat housing cover.
  3. Install the thermostat housing cover bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  4. Install the fuel line bracket.
  5. Install the fuel line bracket bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
  6. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L Engine)»(ref-277850-S28537429092008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Reposition the inlet hose clamp at the water outlet.
  3. Remove the inlet hose from the water outlet.
  4. Remove the water outlet bolts (2).
  5. Remove the water outlet (1).
  6. Remove the thermostat (3).
  1. Install the thermostat (3).
  2. Install the water outlet (1). NOTE: Refer to «FASTENER NOTICE»(ref-277849-S30907907212008012100000) .
  3. Install the water outlet bolts (2). Tighten: Tighten the bolts to 30 N.m (22 lb ft).
  4. Install the inlet hose to the water outlet.
  5. Position the inlet hose clamp at the water outlet.
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  3. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnection and Connection (Auxiliary Battery)»(ref-277854-S37314824542008012100000) or «Battery Negative Cable Disconnection and Connection (Single Battery)»(ref-277854-S29426527292008012100000) .
  4. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  5. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-277954-S13505986422008012100000) .
  6. Disconnect the air conditioning (A/C) compressor clutch electrical connector (5).
  7. Disconnect the A/C cut out switch electrical connector.
  8. Remove the A/C compressor bolts.
  9. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.
  10. Remove the generator positive cable to generator nut.
  11. Remove the positive cable from the generator.
  12. Remove the clip holding the positive cable to the engine front cover.
  13. Remove the battery positive cable junction block to power steering pump bolt (1).
  14. Move the generator positive cable and the junction block bracket aside.
  15. Disconnect the generator electrical connector.
  16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  17. Remove the air conditioning (A/C) compressor/power steering pump bracket bolts.
  18. Reposition the A/C compressor/power steering pump bracket and secure to the side. Do not remove the power steering pump from the bracket. The hoses and battery cables can remain on the power steering pump.
  19. Remove the heater outlet hose bracket bolt from the generator bracket.
  20. Remove the idler pulley.
  21. Remove the generator bracket bolts.
  22. Remove the generator bracket and position to the side. The generator does not require removal. The drive belt tensioner does not require removal.
  23. Remove the oil fill tube. Refer to «Oil Fill Tube Replacement»(ref-277954-S11261754242008012100000) .
  24. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L Engine)»(ref-277850-S28537429092008012100000) .
  25. Reposition the exhaust gas recirculation (EGR) hose clamp at the EGR coolant pipe.
  26. Remove the EGR coolant pipe bolt.
  27. Remove the EGR coolant pipe with O-ring seal from the crossover.
  28. Reposition the turbocharger coolant return pipe hose clamp.
  29. Remove the turbocharger coolant return pipe hose.
  30. Remove the fuel line bracket bolt at the thermostat housing crossover.
  31. Remove the cooling fan pulley. Refer to «Cooling Fan Pulley Replacement (6.6L (LLY) Engine)»(ref-277850-S31035612582008012100000) .
  32. Remove the water pump inlet pipe bolts.
  33. Remove the thermostat housing bolts and nuts.
  34. Remove the thermostat housing, with the bypass pipe.
  35. Remove and discard the thermostat bypass pipe to water pump O-ring seal.
  36. Remove and discard the thermostat housing gaskets.
  37. If necessary, perform the following steps: Remove the thermostat bypass pipe from the thermostat housing. Remove and discard the thermostat bypass pipe O-ring seal. Remove the thermostat cover bolts and cover. Remove the thermostats. Remove and discard the thermostat seals.
  38. If required, clean and inspect the thermostat housing. Refer to «Engine Coolant Thermostat Housing Cleaning and Inspection»(ref-277959-S21754267962008012100000) .
  1. If necessary, perform the following steps: Install NEW seals to the thermostats. Install the thermostats. NOTE: Refer to «Fastener Notice»(ref-277849-S30907907212008012100000) . Install the thermostat cover and bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft). Install a NEW O-ring seal to the thermostat bypass pipe. Install the thermostat bypass pipe to the thermostat housing.
  2. Install a NEW thermostat bypass pipe to water pump O-ring seal.
  3. Install the thermostat housing using NEW gaskets.
  4. Install the thermostat housing bolts and nuts Tighten: Tighten the bolts/nuts to 21 N.m (15 lb ft).
  5. Install the water pump inlet pipe bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  6. Install the cooling fan pulley. Refer to «Cooling Fan Pulley Replacement (6.6L (LLY) Engine)»(ref-277850-S31035612582008012100000) .
  7. Install the fuel line bracket bolt at the thermostat housing crossover. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
  8. Install the turbocharger coolant return pipe hose.
  9. Position the turbocharger coolant return pipe hose clamp.
  10. Install the EGR coolant pipe with O-ring seal to the crossover.
  11. Install the EGR coolant pipe bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  12. Position the EGR hose clamp at the EGR coolant pipe.
  13. Install the water outlet. Refer to «Water Outlet Tube Replacement (6.6L Engine)»(ref-277850-S28537429092008012100000) .
  14. Install the oil fill tube. Refer to «Oil Fill Tube Replacement»(ref-277954-S11261754242008012100000) .
  15. Position the generator bracket.
  16. Install the generator bracket bolts. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  17. Install the idler pulley. Tighten: Tighten the bolt to 43 N.m (32 lb ft).
  18. Install the heater outlet hose bracket bolt to the generator bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
  19. Position the A/C compressor/power steering pump bracket.
  20. Install the A/C compressor/power steering pump bracket bolts. Tighten: Tighten the bolt to 46 N.m (34 lb ft).
  21. Position the generator positive cable and the junction block bracket.
  22. Install the battery positive cable junction block to power steering pump bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  23. Install the clip holding the positive cable to the engine front cover.
  24. Install the positive cable to the generator.
  25. Install the generator positive cable to generator nut. Tighten: Tighten the nut to 9 N.m (80 lb in).
  26. Connect the ECT sensor electrical connector.
  27. Connect the generator electrical connector.
  28. Position the A/C compressor, with the hoses attached.
  29. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  30. Connect the A/C cut out switch electrical connector.
  31. Connect the A/C compressor clutch electrical connector (5).
  32. Install the drive belt. Refer to «Drive Belt Replacement»(ref-277954-S13505986422008012100000) .
  33. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel)»(ref-277850-S28107668452008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Gasoline)»(ref-277850-S14169777482008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Diesel)»(ref-277850-S17539185252008012100000) or «Engine Coolant Fan Upper Shroud Replacement (Manual Transmission - Gasoline)»(ref-277850-S41003245832008012100000) or «Engine Coolant Fan Upper Shroud Replacement (w/RPO HP2)»(ref-277850-S26956976092008012100000) .
  34. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnection and Connection (Auxiliary Battery)»(ref-277854-S37314824542008012100000) or «Battery Negative Cable Disconnection and Connection (Single Battery)»(ref-277854-S29426527292008012100000) .
  35. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  36. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-277954-S16999912012008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Accessory»(ref-277941-S04400394372008012100000) .
  3. Reposition the inlet hose clamp at the water crossover.
  4. Remove the inlet hose from the water crossover.
  5. Reposition the heater inlet hose clamp at the water crossover.
  6. Remove the heater inlet hose from the water crossover.
  7. Reposition the bypass hose clamps at the water crossover and water pump.
  8. Remove the bypass hose.
  9. Remove the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-277854-S16014538152008012100000) or «Generator Replacement (6.6L Engine)»(ref-277854-S16039292232008012100000) or «Generator Replacement (8.1L Engine)»(ref-277854-S23534712002008012100000) .
  10. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(ref-277902-S05383508112008012100000) or «Power Steering Pump Replacement (4.8L, 5.3L, and 6.0L)»(ref-277902-S17019347462008012100000) or «Power Steering Pump Replacement (6.6L Diesel)»(ref-277902-S31373744492008012100000) or «Power Steering Pump Replacement (8.1L)»(ref-277902-S21568160712008012100000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-277902-S41281682512008012100000) .
  11. Remove the generator bracket bolts and nut.
  12. Remove the generator bracket stud.
  13. Remove the generator bracket.
  14. Remove the water crossover bolts.
  15. Remove the water crossover.
  16. Remove and discard the water crossover gaskets.
  17. If replacing the water crossover remove the following: Water outlet bolts (2) Water outlet (1) Thermostat (3)
  1. If replacing the water crossover install the following: Thermostat (3) Water outlet (1) 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 (4.3L)»(ref-277902-S05383508112008012100000) or «Power Steering Pump Replacement (4.8L, 5.3L, and 6.0L)»(ref-277902-S17019347462008012100000) or «Power Steering Pump Replacement (6.6L Diesel)»(ref-277902-S31373744492008012100000) or «Power Steering Pump Replacement (8.1L)»(ref-277902-S21568160712008012100000) or «Power Steering Pump Replacement (5.3L w/RPO HP2)»(ref-277902-S41281682512008012100000) .
  9. Install the generator. Refer to «Generator Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-277854-S16014538152008012100000) or «Generator Replacement (6.6L Engine)»(ref-277854-S16039292232008012100000) or «Generator Replacement (8.1L Engine)»(ref-277854-S23534712002008012100000) .
  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. Refer to «Drive Belt Tensioner Replacement - Accessory»(ref-277941-S04400394372008012100000) .
  17. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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).
  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/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. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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).
  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.
  1. Remove the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-277850-S15621626142008012100000) .
  2. Remove the bypass pipe from the thermostat housing.
  3. Remove and discard the O-ring seals from the bypass pipe and the water pump.
  4. Clean the sealing surfaces of the bypass pipe.
  5. If required, clean and inspect the bypass pipe and thermostat housing. Refer to «Engine Coolant Thermostat Housing Cleaning and Inspection»(ref-277959-S21754267962008012100000) .
  1. Install a NEW O-ring seal onto the bypass pipe.
  2. Install a NEW O-ring seal to the water pump.
  3. Lubricate the O-ring seals with clean engine coolant.
  4. Install the bypass pipe into the thermostat housing.
  5. Install the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-277850-S15621626142008012100000) .
  1. Loosen the air cleaner outlet duct clamp at the mass air flow (MAF)/intake air temperature (IAT) sensor.
  2. Remove the positive crankcase ventilation (PCV) hose.
  3. Remove the air cleaner adapter nut.
  4. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip release from the lip on the throttle body.
  5. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  6. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-277938-S02095851762008012100000) .
  7. Reposition the radiator outlet hose clamps at the surge tank and water pump.
  8. Remove the radiator outlet hose from the surge tank.
  9. Remove the radiator outlet hose from the water pump.
  10. Reposition the water pump inlet hose clamps.
  11. Remove the water pump inlet hose.
  12. Using J 41240 , hold the water pump pulley, remove the water pump pulley bolts. See «Special Tools»(ref-277850-S19943780362008012100000) .
  13. Remove the water pump bolts.
  14. Remove the water pump.
  15. Remove and discard the water pump gaskets.
  16. Clean and inspect the water pump, if necessary. Refer to «Water Pump Cleaning and Inspection»(ref-277938-S11131167422008012100000) .
  1. If reusing the old 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-277849-S30907907212008012100000) .
  3. Install the water pump bolts. Tighten: Tighten the bolts to 45 N.m (33 lb ft).
  4. Using J 41240 , hold the water pump pulley, install the water pump pulley bolts. See «Special Tools»(ref-277850-S19943780362008012100000) . Tighten: Tighten the 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-277938-S02095851762008012100000) .
  11. 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.
  12. Install the air cleaner adapter nut.
  13. Install the PCV hose.
  14. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamps to 4 N.m (35 lb in).
  15. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  16. Inspect the cooling system for leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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. If necessary, remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(ref-277904-S40900535922008012100000) or «Upper Intake Manifold Sight Shield Replacement (6.0L (RPO LQ9))»(ref-277904-S18400695242008012100000) .
  6. Remove the radiator vent inlet hose from the radiator hose clips.
  7. Reposition the inlet hose clamp at the water pump.
  8. Remove the inlet hose from the water pump.
  9. If necessary, remove the fan blade. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
  10. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines)»(ref-277904-S16962271902008012100000) or «Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2)»(ref-277904-S20577162652008012100000) .
  11. Reposition the outlet hose clamp at the water pump.
  12. Remove the outlet hose from the water pump.
  13. Reposition the surge tank outlet hose clamp at the water pump.
  14. Remove the surge tank outlet hose from the water pump.
  15. Reposition the heater inlet hose clamp at the water pump.
  16. Remove the heater inlet hose from the water pump.
  17. Remove the water pump bolts.
  18. Remove the water pump and gaskets.
  19. Discard the water pump gaskets.
IMPORTANTAll gaskets surfaces are to be free of oil or other foreign material during assembly.
  1. Install the water pump and NEW gaskets.
  2. Install the water pump bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). 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 (4.8L, 5.3L, and 6.0L Engines)»(ref-277904-S16962271902008012100000) or «Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2)»(ref-277904-S20577162652008012100000) .
  10. If necessary, install the fan blade. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
  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 «Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))»(ref-277904-S40900535922008012100000) or «Upper Intake Manifold Sight Shield Replacement (6.0L (RPO LQ9))»(ref-277904-S18400695242008012100000) .
  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 4 N.m (35 lb in).
  18. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Remove the drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .
  3. Remove the fan clutch. Refer to «Fan Clutch Replacement (Diesel)»(ref-277850-S37736304992008012100000) or «Fan Clutch Replacement (Gasoline)»(ref-277850-S11335759712008012100000) .
  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.
  1. Place NEW water pump gaskets into place.
  2. Install the water pump. NOTE: Refer to «FASTENER NOTICE»(ref-277849-S30907907212008012100000) .
  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 (Diesel)»(ref-277850-S37736304992008012100000) or «Fan Clutch Replacement (Gasoline)»(ref-277850-S11335759712008012100000) .
  9. Install the drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-277941-S02332021392008012100000) .
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Remove the left wheelhouse inner panel. Refer to «Wheelhouse Panel Replacement»(ref-277879-S17618551252008012100000) .
  2. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-277850-S15621626142008012100000) .
  3. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-277954-S19723851472008012100000) .
  4. Remove the water pump to engine coolant pipe nuts.
  5. Remove the engine wiring harness retainer from the inner stud.
  6. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths.
  7. Remove the water pump.
  8. Remove and discard the water pump O-ring and coolant pipe gasket.
  9. If required, clean and inspect the water pump. Refer to «Water Pump Cleaning and Inspection»(ref-277959-S17903725682008012100000) .
  1. Lubricate the water pump O-ring with engine oil.
  2. Install the engine coolant pipe gasket and water pump O-ring.
  3. Install the water pump. NOTE: Refer to «Fastener Notice»(ref-277849-S30907907212008012100000) .
  4. 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).
  5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud.
  6. Install the water pump to engine coolant pipe nuts. Tighten: Tighten the nuts to 21 N.m (15 lb ft).
  7. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L Engine)»(ref-277850-S15621626142008012100000) .
  8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-277954-S19723851472008012100000) .
  9. Install the left wheelhouse inner panel. Refer to «Wheelhouse Panel Replacement»(ref-277879-S17618551252008012100000) .
  1. Remove the water pump. Refer to «Water Pump Replacement (4.3L)»(ref-277850-S21869186492008012100000) or «Water Pump Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S39211025212008012100000) or «Water Pump Replacement (8.1L)»(ref-277850-S32082901052008012100000) or «Water Pump Replacement (6.6L)»(ref-277850-S17145617782008012100000) .
  2. Remove the engine coolant pipe.
  3. Remove and discard the coolant pipe O-ring seal.
  1. Install a NEW O-ring seal onto the coolant pipe.
  2. Lubricate the O-ring seal with engine coolant.
  3. Install the engine coolant pipe.
  4. Install the water pump. Refer to «Water Pump Replacement (4.3L)»(ref-277850-S21869186492008012100000) or «Water Pump Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S39211025212008012100000) or «Water Pump Replacement (8.1L)»(ref-277850-S32082901052008012100000) or «Water Pump Replacement (6.6L)»(ref-277850-S17145617782008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Reposition the front heater inlet hose clamp (4) from the auxiliary water pump (1).
  3. Remove the front heater inlet hose (6) from the auxiliary water pump (1).
  4. Reposition the rear heater inlet hose clamp (2) from the auxiliary water pump (1).
  5. Remove the rear heater inlet hose (3) from the auxiliary water pump (1).
  6. Remove the heater outlet hose from the clip.
  7. Disconnect the electrical connector (1) from the auxiliary water pump (2).
  8. Remove the nuts (4) from the auxiliary water pump bracket (1).
  9. Remove the auxiliary water pump (1) from the vehicle.
  10. Remove the clips (2) from the auxiliary water pump bracket (1).
  11. Remove the auxiliary water pump (3) from the auxiliary water pump bracket (1).
  1. Install the auxiliary water pump (3) to the auxiliary water pump bracket (1).
  2. Install the clips (2) to the auxiliary water pump bracket (1).
  3. Install the auxiliary water pump (1) to the vehicle.
  4. Install the nuts (4) to the auxiliary water pump bracket (1). Tighten: Tighten the nuts to 9 N.m (80 lb in).
  5. Connect the electrical connector (1) to the auxiliary water pump (2).
  6. Install the heater outlet hose to the clip.
  7. Install the rear heater inlet hose (3) to the auxiliary water pump (1).
  8. Position the rear heater inlet hose clamp (2) to the auxiliary water pump (1).
  9. Install the front heater inlet hose (6) to the auxiliary water pump (1).
  10. Position the front heater inlet hose clamp (4) to the auxiliary water pump (1).
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 powertrain control module (PCM) cover.
  6. Remove the transmission control module (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 (1).
  12. Remove the fan shroud bolts (2).
  13. Remove the upper fan shroud.
  1. Install the upper fan shroud.
  2. Install the fan shroud retainers (1).
  3. Install the fan shroud bolts (2). Tighten: Tighten the bolts to 9 N.m (80 lb in).
  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 to 4 N.m (35 lb in).
  13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  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 powertrain control module (PCM) cover.
  6. Remove the transmission control module (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.
  1. Install the upper fan shroud.
  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 to 4 N.m (35 lb in).
  13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  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 (2).
  8. Remove the upper fan shroud.
  1. Install the upper fan shroud. NOTE: Refer to «FASTENER NOTICE»(ref-277849-S30907907212008012100000) .
  2. Install the fan shroud retainers (1)
  3. Install the fan shroud bolts (2). Tighten: Tighten the bolts to 9 N.m (80 lb in).
  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 to 4 N.m (35 lb in).
  8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  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.
  1. Install the upper fan shroud.
  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 to 4 N.m (35 lb in).
  8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  1. Loosen the air cleaner outlet duct clamps from the throttle body.
  2. Loosen the air cleaner outlet duct clamps from the mass air flow (MAF) sensor.
  3. Remove the air cleaner outlet duct.
  4. Remove the hybrid control module (HCM). Refer to «Powertrain Control Interface Module Replacement (5.3L Engine w/RPO HP2)»(ref-277905-S13537703952008012100000) .
  5. Remove the throttle body heater hose retainer from the fan shroud.
  6. Remove the inlet radiator hose retainer from the fan shroud.
  7. Remove the fan shroud retainers.
  8. Remove the fan shroud bolts.
  9. Remove the upper fan shroud (1).
  1. Install the upper fan shroud (1).
  2. Install the fan shroud bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  3. Install the fan shroud retainers.
  4. Install the inlet radiator hose retainer to the fan shroud.
  5. Install the throttle body heater hose retainer to the fan shroud.
  6. Install the HCM. Refer to «Powertrain Control Interface Module Replacement (5.3L Engine w/RPO HP2)»(ref-277905-S13537703952008012100000) .
  7. Install the air cleaner outlet duct.
  8. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  9. Tighten the air cleaner outlet duct clamp at the MAF sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  1. Remove the cooling fan. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
  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.
  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 (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
  1. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-277850-S20590404252008012100000) .
  2. Remove the radiator outlet hose for the 4.3L engine, or the 4.8L, 5.3L and 6.0L engines. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  3. Disconnect the engine oil cooler lines from the radiator, if necessary. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  4. Disconnect the transmission oil cooler lines from the radiator, if necessary. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-277952-S11288139652008012100000) .
  5. Remove the radiator bolts.
  6. Remove the radiator.
  1. Install the radiator.
  2. Install the radiator bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. Connect the transmission oil cooler lines to the radiator, if necessary. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-277952-S11288139652008012100000) .
  4. Connect the engine oil cooler lines to the radiator, if necessary. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  5. Install the radiator outlet hose for the 4.3L engine, or the 4.8L, 5.3L and 6.0L engines. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  6. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-277850-S20590404252008012100000) .
  1. Remove the radiator inlet hose for the 8.1L engine. Refer to «Radiator Inlet Hose Replacement (4.3L)»(ref-277850-S26418632742008012100000) or «Radiator Inlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S24714570742008012100000) or «Radiator Inlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S14319689852008012100000) or «Radiator Inlet Hose Replacement (6.6L)»(ref-277850-S22013468132008012100000) or «Radiator Inlet Hose Replacement (8.1L)»(ref-277850-S29098743722008012100000) .
  2. Remove the radiator outlet hose for the 8.1L engine. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  3. Remove the lower fan shroud. Refer to «Engine Coolant Fan Lower Shroud Replacement»(ref-277850-S42558773622008012100000) .
  4. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-277874-S19644157782008012100000) .
  5. Remove the push pin from the air cleaner adapter (2).
  6. Remove the bolts from the air cleaner adapter (2).
  7. Remove the air cleaner adapter (2) from the vehicle.
  8. Reposition the surge tank inlet hose clamp at the radiator.
  9. Remove the surge tank inlet hose from the radiator.
  10. Disconnect the engine oil cooler lines from the radiator, if necessary. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  11. Disconnect the transmission oil cooler lines from the radiator, if necessary. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-277952-S11288139652008012100000) for the 4L80-E/4L65-E transmission, or «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-277908-S11819022252008012100000) for the Allison transmission.
  12. Remove the radiator bolts.
  13. Remove the radiator.
  1. Install the radiator.
  2. Install the radiator bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. Connect the transmission oil cooler lines to the radiator, if necessary. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-277952-S11288139652008012100000) for the 4L80-E/4L85-E transmission, or «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-277908-S11819022252008012100000) for the Allison transmission.
  4. Connect the engine oil cooler lines to the radiator, if necessary. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-277850-S29113731482008012100000) .
  5. Install the surge tank inlet hose to the radiator.
  6. Reposition the surge tank inlet hose clamp at the radiator.
  7. Install the air cleaner adapter (2) to the vehicle.
  8. Install the bolts to the air cleaner adapter (2). Tighten: Tighten the bolts to 9 N.m (80 lb in).
  9. Install the push pin to the air cleaner adapter (2).
  10. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-277874-S19644157782008012100000) .
  11. Install the lower fan shroud. Refer to «Engine Coolant Fan Lower Shroud Replacement»(ref-277850-S42558773622008012100000) .
  12. Install the radiator outlet hose for the 8.1L engine. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  13. Install the radiator inlet hose for the 8.1L engine. Refer to «Radiator Inlet Hose Replacement (4.3L)»(ref-277850-S26418632742008012100000) or «Radiator Inlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S24714570742008012100000) or «Radiator Inlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S14319689852008012100000) or «Radiator Inlet Hose Replacement (6.6L)»(ref-277850-S22013468132008012100000) or «Radiator Inlet Hose Replacement (8.1L)»(ref-277850-S29098743722008012100000) .
  1. Remove the radiator inlet hose for the 6.6L engine. Refer to «Radiator Inlet Hose Replacement (4.3L)»(ref-277850-S26418632742008012100000) or «Radiator Inlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S24714570742008012100000) or «Radiator Inlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S14319689852008012100000) or «Radiator Inlet Hose Replacement (6.6L)»(ref-277850-S22013468132008012100000) or «Radiator Inlet Hose Replacement (8.1L)»(ref-277850-S29098743722008012100000) .
  2. Remove the radiator outlet hose for the 6.6L engine. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  3. Remove the engine fan. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
  4. Remove the lower fan shroud. Refer to «Engine Coolant Fan Lower Shroud Replacement»(ref-277850-S42558773622008012100000) .
  5. If necessary, disconnect the automatic transmission oil cooler lines from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-277908-S11819022252008012100000) .
  6. Remove the radiator bolts.
  7. Remove the radiator.
  1. Install the radiator.
  2. Install the radiator bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. If necessary, connect the automatic transmission oil cooler lines to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-277908-S11819022252008012100000) .
  4. Install the lower fan shroud. Refer to «Engine Coolant Fan Lower Shroud Replacement»(ref-277850-S42558773622008012100000) .
  5. Install the engine fan. Refer to «Fan Replacement (Diesel)»(ref-277850-S12386650402008012100000) or «Fan Replacement (Mechanical)»(ref-277850-S26259650622008012100000) .
  6. Install the radiator outlet hose for the 6.6L engine. Refer to «Radiator Outlet Hose Replacement (4.3L)»(ref-277850-S10848662382008012100000) or «Radiator Outlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S36146991322008012100000) or «Radiator Outlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S13948384132008012100000) or «Radiator Outlet Hose Replacement (6.6L)»(ref-277850-S12877974382008012100000) or «Radiator Outlet Hose Replacement (8.1L)»(ref-277850-S02035451012008012100000) .
  7. Install the radiator inlet hose for the 6.6L engine. Refer to «Radiator Inlet Hose Replacement (4.3L)»(ref-277850-S26418632742008012100000) or «Radiator Inlet Hose Replacement (4.8L, 5.3L, and 6.0L)»(ref-277850-S24714570742008012100000) or «Radiator Inlet Hose Replacement (5.3L w/RPO HP2)»(ref-277850-S14319689852008012100000) or «Radiator Inlet Hose Replacement (6.6L)»(ref-277850-S22013468132008012100000) or «Radiator Inlet Hose Replacement (8.1L)»(ref-277850-S29098743722008012100000) .
  1. Remove the radiator. Refer to «Radiator Replacement (4.3, 4.8, 5.3, and 6.0L)»(ref-277850-S42000307572008012100000) or «Radiator Replacement (8.1L)»(ref-277850-S41515550482008012100000) or «Radiator Replacement (Diesel)»(ref-277850-S36377679692008012100000) .
  2. Remove the radiator air baffle retainers.
  3. Remove the radiator air baffles.
  1. Install the radiator air baffles.
  2. Install the radiator air baffle retainers.
  3. Install the radiator. Refer to «Radiator Replacement (4.3, 4.8, 5.3, and 6.0L)»(ref-277850-S42000307572008012100000) or «Radiator Replacement (8.1L)»(ref-277850-S41515550482008012100000) or «Radiator Replacement (Diesel)»(ref-277850-S36377679692008012100000) .
  1. Remove the radiator air upper baffle retainers.
  2. Remove the radiator air upper baffle.
  1. Install the radiator air upper baffle.
  2. Install the radiator air upper baffle retainers.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  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 (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-277879-S31943219262008012100000) .
  2. Remove the front drive axle shield. Refer to «Shield Replacement»(ref-277880-S16352542082008012100000) .
  3. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  5. Disconnect the coolant heater electrical connector.
  6. Remove the coolant heater from the engine block.
  7. Remove any burrs, sealer, paint or other rough spots.
  1. If reusing the old coolant heater, apply thread sealant to the to the threads. Refer to «Sealers, Adhesives, and Lubricants»(ref-277939-S35681355302008012100000) for the correct part number.
  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.
  4. Lower the vehicle.
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  6. Install the front drive axle shield. Refer to «Shield Replacement»(ref-277880-S16352542082008012100000) .
  7. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-277879-S31943219262008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-277896-S27966091872008012100000) .
  3. Remove the right engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-277954-S03797127992008012100000) .
  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
  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.
  2. Align the coolant heater element to point towards the top of the engine.
  3. Tightly push the coolant heater into the engine block.
  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).
  5. Connect the heater cord to the coolant heater.
  6. Remove the right engine mount. Refer to «Engine Mount Replacement - Right Side»(ref-277954-S03797127992008012100000) .
  7. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-277896-S27966091872008012100000) .
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  9. Inspect for coolant leaks.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  2. Disconnect the block heater cord from the block heater.
  3. Remove the engine block heater.
  1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the engine block heater.
  2. Install the engine block heater into the block. Tighten: Tighten the coolant heater to 60 N.m (40 lb ft).
  3. Connect the block heater cord to the block heater.
  4. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  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 (Static Fill)»(ref-277850-S07555853772008012100000) or «Draining and Filling Cooling System (w/RPO HP2)»(ref-277850-S31192445052008012100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-277850-S00482587952008012100000) .
  6. Inspect the cooling system for leaks.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  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 bolts to 8 N.m (71 lb in).
  3. Connect the coolant heater electrical connector (2).
  4. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-277851-S21776392712008012100000) .
  2. Disconnect the coolant heater cord from the coolant heater.
  3. Remove the coolant heater cord clip (2) from the front brake pipe front pipe.
  4. Remove the coolant heater cord retainer (1) and bolt (4). Ensure that the washer (3) is also removed.
  5. 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 retainer (1) and bolt (4). Ensure that the washer (3) is installed under the cord clip and on the bolt (4). Tighten: Tighten the bolt to 8 N.m (71 lb in).
  3. Install the coolant heater cord clip (2) to the front brake pipe front pipe.
  4. Connect the coolant heater cord to the coolant heater.
  5. Lower the vehicle.

More articles — Engine Cooling System