Engine Cooling System: Removal & Installation Chevrolet SSR I

Removal Procedure

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
2. Remove the surge tank front bolt at the front mounting bracket.
3. Disengage tension on the surge tank inlet hose clamp (1) using the J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
4. Disconnect the surge tank inlet hose (1) from the surge tank.
5. Disengage tension on the surge tank outlet hose clamp using the J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
6. Disconnect the surge tank outlet hose (3) from the surge tank.
7. Disengage tension on the throttle body coolant hose (2) using the J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
8. Disconnect the throttle body coolant hose (2) from the surge tank.
9. Pull up on the rear of the surge tank to remove from the rear mounting bracket.
10. Remove the surge tank.

Installation Procedure

1. Install the surge tank into the rear mounting bracket.
2. Connect the surge tank outlet hose (3) to the surge tank.
3. Engage tension on the surge tank outlet hose clamp.
4. Connect the surge tank inlet hose (1) to the surge tank.
5. Engage tension on the surge tank inlet hose clamp.
6. Connect the throttle body coolant hose (2) to the surge tank.
7. Engage the tension on the throttle body coolant hose clamp.
8. Install the front surge tank bolt at the mounting bracket. Tighten: Tighten the nut to 9 N.m (80 lb in).
9. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
2. Disengage tension and reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
3. Disconnect the surge tank inlet hose (1) from the surge tank.
4. Disengage tension and reposition the clamp (1) at the radiator.
5. Disconnect the surge tank inlet hose (1) from the radiator.
6. Remove the surge tank inlet hose (1) assembly from the vehicle.

1. Install the surge tank inlet hose (1) to the surge tank inlet hose tee at the proper position for correct surge tank installation.
2. Install a new hose clamp. Secure the clamp.
3. Install the surge tank inlet hose (1) to the radiator.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls.
3. Disengage tension on the radiator inlet hose clamp at the radiator using J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
4. Disconnect the radiator inlet hose (1) from the radiator.
5. Disengage tension on the radiator inlet hose clamp at the engine using J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
6. Disconnect the radiator inlet hose (1) from the engine.
7. Remove the radiator inlet hose (1).

1. Install the radiator inlet hose (1).
2. Connect the radiator inlet hose (1) to the engine.
3. Engage tension on the radiator inlet hose clamp at the engine using J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
4. Connect the radiator inlet hose (1) to the radiator.
5. Engage tension on the radiator inlet hose clamp at the radiator using J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls.
3. Disengage the tension on the radiator outlet hose clamp at the thermostat housing using the J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
4. Disconnect the radiator outlet hose (2) from the thermostat housing.
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
6. Disengage tension on the radiator outlet hose clamp at the radiator using J 38185 . See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
7. Disconnect the radiator outlet hose (2) from the radiator.
8. Remove the radiator outlet hose (2).

1. Install the radiator outlet hose (2).
2. Connect the radiator outlet hose (2) to the radiator.
3. Engage tension on the radiator outlet hose clamp at the radiator.
4. Lower the vehicle.
5. Connect the radiator outlet hose to the thermostat housing.
6. Engage tension on the radiator outlet hose clamp at the thermostat housing.
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

1. Remove the air filter housing. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls 4.8L, 5.3L, and 6.0L.
2. Disconnect the cooling fan electrical connector (1).
3. Reposition the tie straps that secure the cooling fan assembly to the radiator.
4. Pull up on the cooling fan assembly.
5. Remove the cooling fan assembly.

1. Install the electric cooling fan assembly. Align the cooling fan assembly into the mounting tabs on the radiator.
2. Reposition the tie straps that secure the cooling fan assembly to the radiator.
3. Connect the cooling fan electrical connector (1).
4. Install the air filter housing. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls 4.8L, 5.3L, and 6.0L.

1. Remove the condenser fan low relay nut (1).
2. Lift the relay (2) and harness connector (3) up and disconnect the relay (2).

1. Install the condenser fan low relay (2) into the harness connectors (3).
2. Install the relay (2) onto the mounting stud and install the nut (1). Tighten: Tighten the nut to 6 N.m (53 lb in).

1. Remove the condenser fan high relay nut (1).
2. Lift the relay (2) and harness connector (3) up and disconnect the relay (2).

1. Install the condenser fan high relay (2) into the harness connectors (3).
2. Install the relay (2) onto the mounting stud and install the nut (1). Tighten: Tighten the nut to 6 N.m (53 lb in).

1. Remove the radiator outlet hose.
2. Remove the water pump inlet bolts.
3. Remove the water pump inlet and thermostat from the water pump.

1. Install the thermostat and water pump inlet to the water pump.
2. Install the water pump inlet bolts. Tighten: Tighten the water pump inlet bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose.

1. Remove the radiator outlet hose.
2. Remove the water pump inlet bolts.
3. Remove the water pump inlet and thermostat from the water pump.

1. Install the thermostat and water pump inlet to the water pump.
2. Install the water pump inlet bolts. Tighten: Tighten the water pump inlet bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose.

1. Remove the intake manifold only if servicing the rear air bleed plugs. Refer to «Intake Manifold Replacement»(ref-187833-S33717649332005090100000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
2. Remove the coolant air bleed pipe bolts (1).
3. Remove the coolant air bleed pipe (2) with gaskets (3).
4. Remove the gaskets from the coolant air bleed pipe and covers.
5. Discard the gaskets.
6. Remove the coolant air bleed hose (1) from the pipe (2).

1. Install the coolant air bleed hose (1) onto the pipe (2).
2. Install the gaskets onto the coolant air bleed pipe.
3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads.
4. Install the coolant air bleed pipe bolts (1). Tighten: Tighten the bolts 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. If the rear air bleed plugs were serviced, install the intake manifold. Refer to «Intake Manifold Replacement»(ref-187833-S33717649332005090100000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.

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. Drain cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
2. Remove electric cooling fan. Refer to «Cooling Fan Replacement - Electric»(ref-187839-S39311177672005090100000) .
3. Reposition the inlet hose clamp at the water pump.
4. Remove the inlet hose from the water pump.
5. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-187833-S30017336072005090100000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
6. Reposition the outlet hose clamp at the water pump.
7. Remove the outlet hose from the water pump.
8. Reposition the surge tank outlet hose clamp at the water pump.
9. Remove the surge tank outlet hose from the water pump.
10. Reposition the heater inlet hose clamp at the water pump.
11. Remove the heater inlet hose from the water pump.
12. Remove the water pump bolts.
13. Remove the water pump and gaskets.
14. Discard the water pump gaskets.

1. Install the water pump and NEW gaskets.
2. Install the water pump bolts. Tighten: Tighten the water pump bolts a first pass to 15 N.m (11 lb ft). Tighten the water pump bolts a final pass to 30 N.m (22 lb ft).
3. Install the heater inlet hose to the water pump.
4. Position the heater inlet hose clamp at the water pump.
5. Install the surge tank outlet hose to the water pump.
6. Position the surge tank outlet hose clamp at the water pump.
7. Install the outlet hose to the water pump.
8. Position the outlet hose clamp at the water pump.
9. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-187833-S30017336072005090100000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
10. Install the inlet hose to the water pump.
11. Position the inlet hose clamp at the water pump.
12. Install electric cooling fan. Refer to «Cooling Fan Replacement - Electric»(ref-187839-S39311177672005090100000) .
13. Fill cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

Drain Cock Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Place a drain pan under the right side lower radiator mount.
3. Remove the radiator drain cock.
4. Clean or replace the seal and stem as necessary.

1. Install the radiator drain cock.
2. Tighten the radiator drain cock by hand only.
3. Lower the vehicle.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

1. Remove the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric»(ref-187839-S39311177672005090100000) .
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
3. Remove the condenser. Refer to «Condenser Replacement»(ref-187855-S36212067842005090100000) in Heating, Ventilation and Air Conditioning.
4. Use the J 38185 to remove the upper radiator hose (1) from the radiator. See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
5. Use the J 38185 to remove the lower radiator hose (2) from the radiator. See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
6. Remove the vent hose from the radiator.
7. Disconnect both transmission oil cooler lines from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187837-S23117359872005090100000) in Automatic Transmission - 4L60-E/4L65-E.
8. Remove the radiator.

1. Install the radiator.
2. Connect both transmission oil cooler lines to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187837-S23117359872005090100000) in Automatic Transmission - 4L60-E/4L65-E.
3. Install the vent hose from the radiator.
4. Use the J 38185 to install the lower radiator hose (2) from the radiator. See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
5. Use the J 38185 to install the upper radiator hose (1) from the radiator. See «Special Tools and Equipment»(ref-187839-S19047857302005090100000) .
6. Install the condenser. Refer to «Condenser Replacement»(ref-187855-S36212067842005090100000) in Heating, Ventilation and Air Conditioning.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
8. Install the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric»(ref-187839-S39311177672005090100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
2. Disconnect the mass air flow (MAF) sensor wire (1) from the radiator support retainer clip.
3. Disconnect the surge tank inlet hose assembly from the radiator support tabs.
4. Remove the radiator support bolts.
5. Remove the radiator support.

1. Install the radiator support.
2. Install the radiator support bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Connect the surge tank inlet hose assembly to the radiator support tabs.
4. Connect MAF sensor wire (1) to the radiator support retainer clip.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-187797-S29530812492005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Disconnect the coolant heater electrical connector (2).
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

1. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads.
2. Install the coolant heater to the engine block. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-187839-S38425357962005090100000) .

1. Disconnect the coolant heater cord from the coolant heater (1).
2. Remove the coolant heater cord clip from the engine harness.
3. Remove heater cord from vehicle

1. Install heater cord to vehicle.
2. Connect the coolant heater cord to the coolant heater (1).
3. Install the coolant heater cord clip to the engine harness.