Home ReviewsRefund
Home/Chevrolet/Tahoe/Chevrolet Tahoe II (1999-2006)/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 Tahoe II

Cooling System (Mechanical) ~6139 words

Removal Procedure

  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Remove the air cleaner assembly.
  3. Remove the surge tank overflow hose from the surge tank.
  4. Disconnect the low coolant level switch electrical connector (3).
  5. Reposition the surge tank inlet hose clamp.
  6. Remove the surge tank inlet (1) hose from the surge tank.
  7. Reposition the surge tank outlet hose clamp.
  8. Remove the surge tank outlet hose (2) from the surge tank.
  9. Remove the bolt from the surge tank.
  10. Remove the nut from the surge tank.
  11. 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.
  6. Install the surge tank inlet hose (1) to the surge tank.
  7. Position the surge tank inlet hose clamp.
  8. Connect the low coolant level switch electrical connector (3).
  9. Install the surge tank overflow hose.
  10. Install the air cleaner assembly.
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 at 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»(ref-175731-S33607794312005042600000) .

Surge Tank Hose/Pipe Replacement - Outlet (4.8L, 5.3L, and 6.0L Engines)

J 43181 Heater Line Quick Connect Release Tool

  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 air cleaner outlet duct.
  4. If equipped without regular production option (RPO) C36 auxiliary heater, remove the surge tank/heater outlet hose (1) from the mounting clip.
  5. If equipped with RPO C36 auxiliary heater, remove the surge tank/heater outlet hose (1) from the mounting clip.
  6. Install the J 43181 to the surge tank outlet hose.
  7. Close the J 43181 around the surge tank outlet hose.
  8. Firmly pull the J 43181 into the quick connect end of the outlet hose.
  9. If equipped without RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module.
  10. If equipped with RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module.
  11. Reposition the surge tank outlet hose clamp at the surge tank.
  12. Remove the surge tank outlet hose (2) from the surge tank.
  13. Reposition the surge tank outlet hose clamp at the water pump.
  14. Remove the surge tank outlet hose from the water pump.
  15. Remove the surge tank outlet hose.
  1. Install the surge tank outlet hose.
  2. Install the surge tank outlet hose to the water pump.
  3. Position the surge tank outlet hose clamp to the water pump.
  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. If equipped with RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module.
  7. If equipped without RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module. Firmly push the hose onto the heater and blower module pipe until an audible click is heard.
  8. If equipped with RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip.
  9. If equipped without RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip.
  10. Install the air cleaner outlet duct.
  11. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
  12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 air cleaner outlet duct.
  4. If necessary, remove the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, 6.0L (LQW4))»(ref-158859-S00120332282005051100000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L (LQ9))»(ref-158859-S02060676312005051100000) .
  5. Remove the radiator vent inlet hose from the radiator inlet hose clips.
  6. Reposition the inlet hose clamp from the radiator.
  7. Remove the inlet hose from the radiator.
  8. Remove the inlet hose clip from the fan shroud.
  9. Reposition the inlet hose clamp from the water outlet.
  10. Remove the inlet hose from the water outlet.
  1. Install the inlet hose to the water outlet.
  2. Reposition the inlet hose clamp to the water outlet.
  3. Install the inlet hose clip to the fan shroud.
  4. Install the inlet hose to the radiator.
  5. Reposition the inlet hose clamp to the radiator.
  6. Install the radiator vent inlet hose to the radiator inlet hose clips.
  7. If necessary, install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, 6.0L (LQ4))»(ref-158859-S00120332282005051100000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L (LQ9))»(ref-158859-S02060676312005051100000) .
  8. Install the air cleaner outlet duct.
  9. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Reposition the inlet hose clamp from the radiator.
  3. Remove the inlet hose from the radiator.
  4. Reposition the inlet hose clamp from the water outlet.
  5. Remove the inlet hose from the water outlet.
  1. Install the inlet hose to the water outlet.
  2. Reposition the inlet hose clamp to the water outlet.
  3. Install the inlet hose to the radiator.
  4. Reposition the inlet hose clamp to the radiator.
  5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 air cleaner outlet duct.
  4. Reposition the outlet hose clamp from the water pump.
  5. Remove the outlet hose from the water pump.
  6. Reposition the outlet hose clamp from the radiator.
  7. Remove the outlet hose from the radiator.
  1. Install the outlet hose to the radiator.
  2. Reposition the outlet hose clamp to the radiator.
  3. Install the outlet hose to the water pump.
  4. Reposition the outlet hose clamp to 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 air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Reposition the outlet hose clamp from the radiator.
  3. Remove the radiator outlet hose from the radiator.
  4. Reposition the surge tank outlet hose clamp from the surge tank.
  5. Remove the surge tank outlet hose (2) from the surge tank.
  6. Reposition the outlet hose clamp from the water pump.
  7. Remove the outlet hose from the water pump.
  1. Install the outlet hose to the water pump.
  2. Reposition the outlet hose clamp to the water pump.
  3. Install the surge tank outlet hose (2) to the surge tank.
  4. Reposition the surge tank outlet hose clamp to the surge tank.
  5. Install the radiator outlet hose to the radiator.
  6. Reposition the outlet hose clamp to the radiator.
  7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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»(ref-175731-S33607794312005042600000) .
  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-175731-S06848035852005091200000) .
  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. Gently pull the oil cooler pipe fittings straight out from the radiator quick connect fittings.
  3. If equipped with a 8.1L engine, remove the oil cooler hoses from the clip
  4. Raise and suitably support the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
  5. If equipped, remove the engine shield bolts.
  6. Remove the engine shield.
  7. 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.
  8. 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: Remove the oil cooler hose assembly. Connect the quick connect fittings (1) at the engine. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . 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, install the oil cooler hoses to the clip.
  8. Connect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-175731-S06848035852005091200000) .

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-175731-S06848035852005091200000) .
  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. If equipped with a 8.1L engine, remove the oil cooler hoses from the clip.
  4. Raise and suitably support the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
  5. Place jack or utility stands at the rear of the vehicle.
  6. If equipped, remove the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-187666-S17843951582005090100000) .
  7. If equipped, remove the front differential carrier shield. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
  8. Place an adjustable jack under the front differential carrier.
  9. Remove the inner axle housing nuts and washers from the bracket.
  10. Remove the differential carrier upper mounting bolt and nut.
  11. Pivot the differential carrier forward and down on the lower mount bolt while it is being supported by the adjustable jack.
  12. Secure the differential carrier to the jack.
  13. Remove the differential carrier lower mounting bolt and nut.
  14. Lower the jack 4 to 6 inches.
  15. 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.
  16. 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-175132-S17785009232005041500000) . 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-304051-S21802347052008110500000) .
  10. If equipped, install the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-187666-S17843951582005090100000) .
  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-175731-S06848035852005091200000) .

Fan Replacement

Tools Required

  1. J 46406 Fan Clutch Remover and Installer
  2. J 41240-5A Fan Clutch Wrench
  1. Remove the upper fan shroud. Refer to «FAN SHROUD REPLACEMENT - Upper (W/O M74)»(ref-175731-S30704508162005042600000) or «FAN SHROUD REPLACEMENT - Upper (W/M74)»(ref-175731-S26759537742005042600000) .
  2. Install the J 46406 and the J 41240-5A to the fan clutch.
  3. Remove the fan hub nut from the water pump in a counterclockwise rotation.
  4. Lay the fan blade face down on a workbench.
  5. Remove the fan clutch bolts from the rear of the fan blade, if necessary.
  6. 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 bolts.
  2. Install the fan clutch onto the fan blade, if necessary. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
  3. Install the fan clutch bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
  4. Install the fan blade.
  5. Install the J 46406 and the J 41240-5A to the fan clutch. Tighten: Tighten the fan clutch nut clockwise to 56 N.m (41 lb ft).
  6. Install the upper fan shroud. Refer to «FAN SHROUD REPLACEMENT - Upper (W/O M74)»(ref-175731-S30704508162005042600000) or «FAN SHROUD REPLACEMENT - Upper (W/M74)»(ref-175731-S26759537742005042600000) .

Fan Clutch Replacement

Tools Required

  1. J 46406 Fan Clutch Remover and Installer
  2. J 41240-5A Fan Clutch Wrench
  1. Remove the upper fan shroud. Refer to «FAN SHROUD REPLACEMENT - Upper (W/O M74)»(ref-175731-S30704508162005042600000) or «FAN SHROUD REPLACEMENT - Upper (W/M74)»(ref-175731-S26759537742005042600000) .
  2. Install the J 46406 and the J 41240-5A to the fan clutch.
  3. Remove the fan hub nut from the water pump in a counterclockwise rotation.
  4. Lay the fan blade face down on a workbench.
  5. Remove the fan clutch bolts from the rear of the fan blade.
  6. Separate the fan clutch from the fan blade.
  1. Install the fan clutch bolts.
  2. Install the fan clutch onto the fan blade. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
  3. Install the fan clutch bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
  4. Install the fan blade.
  5. Install the J 46406 and the J 41240-5A to the fan clutch. Tighten: Tighten the fan clutch nut clockwise to 56 N.m (41 lb ft).
  6. Install the upper fan shroud. Refer to «FAN SHROUD REPLACEMENT - Upper (W/O M74)»(ref-175731-S30704508162005042600000) or «FAN SHROUD REPLACEMENT - Upper (W/M74)»(ref-175731-S26759537742005042600000) .
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 HOSE REPLACEMENT - Inlet (4.8L, 5.3L, and 6.0L Engines)»(ref-175731-S05323663922005042600000) or «RADIATOR HOSE REPLACEMENT - Inlet (8.1L Engine)»(ref-175731-S06607734912005042600000) .
  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. Refer to «RADIATOR HOSE REPLACEMENT - Inlet (4.8L, 5.3L, and 6.0L Engines)»(ref-175731-S05323663922005042600000) or «RADIATOR HOSE REPLACEMENT - Inlet (8.1L Engine)»(ref-175731-S06607734912005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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-175132-S17785009232005041500000) .
  3. Install the water outlet bolts (2). Tighten: Tighten the water outlet 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»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Remove the drive belt tensioner. Refer to «DRIVE BELT TENSIONER REPLACEMENT -- ACCESSORY»(ref-176772-S20278798422005051100000) .
  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 (4.8L, 5.3L & 6.0L ENGINES)»(ref-138808-S42710566352002042300000) or «GENERATOR (8.1L ENGINE)»(ref-138808-S37977286942002042300000) .
  10. Remove the power steering pump. Refer to «POWER STEERING PUMP REPLACEMENT (4.8 L, 5.3 L, & 6.0L)»(ref-178409-S14847822572005061500000) or «POWER STEERING PUMP REPLACEMENT (8.1 L)»(ref-178409-S10555711912005061500000) .
  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 water outlet 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 water crossover bolts to 50 N.m (37 lb ft).
  5. Install the generator bracket.
  6. Install the generator bracket stud. Tighten: Tighten the generator bracket stud to 20 N.m (15 lb ft).
  7. Install the generator bracket bolts and nut. Tighten: Tighten the generator bracket bolts and nut to 50 N.m (37 lb ft).
  8. Install the power steering pump. Refer to «POWER STEERING PUMP REPLACEMENT (4.8 L, 5.3 L, & 6.0L)»(ref-178409-S14847822572005061500000) or «POWER STEERING PUMP REPLACEMENT (8.1 L)»(ref-178409-S10555711912005061500000) .
  9. Install the generator. Refer to «GENERATOR (4.8L, 5.3L & 6.0L ENGINES)»(ref-138808-S42710566352002042300000) or «GENERATOR (8.1L ENGINE)»(ref-138808-S37977286942002042300000) .
  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-176772-S20278798422005051100000) .
  17. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Remove the coolant air bleed pipe 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 studs (1). Tighten: Tighten the coolant air bleed pipe studs to 12 N.m (106 lb in).
  5. Install the coolant air bleed pipe covers (2) and bolts (1). Tighten: Tighten the coolant air bleed pipe cover bolts to 12 N.m (106 lb in).
  6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. If necessary, remove the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, 6.0L (LQ4))»(ref-158859-S00120332282005051100000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L (LQ9))»(ref-158859-S02060676312005051100000) .
  2. Reposition the coolant air bleed hose clamp at the throttle body.
  3. Remove the coolant air bleed hose from the throttle body.
  4. Reposition the hose clamp at the pipe.
  5. 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 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. If necessary, install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, 6.0L (LQ4))»(ref-158859-S00120332282005051100000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L (LQ9))»(ref-158859-S02060676312005051100000) .
  6. Add engine coolant, if necessary.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, 6.0L (LQ4))»(ref-158859-S00120332282005051100000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L (LQ9))»(ref-158859-S02060676312005051100000) .
  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. Remove the fan blade. Refer to «Fan Replacement»(ref-175731-S30195461822005042600000) .
  10. Remove the accessory drive belt. Refer to «DRIVE BELT REPLACEMENT -- ACCESSORY»(ref-158859-S35148892272005051100000) .
  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 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-158859-S35148892272005051100000) .
  10. Install the fan blade. Refer to «Fan Replacement»(ref-175731-S30195461822005042600000) .
  11. Install the inlet hose to the water pump.
  12. Position the inlet hose clamp at the water pump.
  13. Install the engine vent inlet hose to the radiator hose clips.
  14. If necessary, install the engine sight shield. Refer to «ENGINE SIGHT SHIELD REPLACEMENT (4.8L, 5.3L, 6.0L (LQ4))»(ref-158859-S00120332282005051100000) or «ENGINE SIGHT SHIELD REPLACEMENT (6.0L (LQ9))»(ref-158859-S02060676312005051100000) .
  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 air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
  18. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Remove the drive belt. Refer to «DRIVE BELT TENSIONER REPLACEMENT -- ACCESSORY»(ref-176772-S20278798422005051100000) .
  3. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-175731-S14003176082005042600000) .
  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-175132-S17785009232005041500000) .
  3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 50 N.m (37 lb ft).
  4. Install the bypass hose.
  5. Position the bypass hose clamps at the water pump and water crossover.
  6. Install the outlet hose to the water pump.
  7. Position the outlet hose clamp at the water pump.
  8. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-175731-S14003176082005042600000) .
  9. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT -- ACCESSORY»(ref-176772-S04987143402005051100000) .
  10. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Remove the radiator drain cock.
  1. Install the radiator drain cock.
  2. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 screw to 7 N.m (62 lb in).
  8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp screw to 7 N.m (62 lb in).
  1. Loosen the air cleaner outlet duct clamps from the throttle body.
  2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
  3. Remove the air cleaner outlet duct.
  4. Remove the A/C line retainer from the fan shroud.
  5. Remove the engine harness clip from the PCM cover.
  6. Remove the TCM cover bolts.
  7. Remove TCM cover from the fan shroud.
  8. Loosen the TCM electrical connector bolts.
  9. Disconnect the TCM electrical connectors (1).
  10. Remove the TCM and cover.
  11. Remove the fan shroud retainers.
  12. Remove the fan shroud bolts
  13. Remove the upper fan shroud.
  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 screws to 7 N.m (62 lb in).
  13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp screws to 7 N.m (62 lb in).
  1. Remove the cooling fan. Refer to «Fan Replacement»(ref-175731-S30195461822005042600000) .
  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»(ref-175731-S30195461822005042600000)
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000)
  2. Reposition the inlet hose clamp from the radiator.
  3. Remove the inlet hose from the radiator.
  4. Reposition the outlet hose clamp from the radiator.
  5. Remove the radiator outlet hose from the radiator.
  6. Remove the lower fan shroud. Refer to «FAN SHROUD REPLACEMENT - Lower»(ref-175731-S28941742142005042600000) .
  7. Reposition the radiator vent inlet hose clamp from the radiator.
  8. Remove the vent inlet hose from the radiator.
  9. Remove the engine oil cooler lines from the radiator. Refer to «Engine Oil Cooler Hose/Pipe Replacement (2WD)»(ref-175731-S19515451392005042600000) or «Engine Oil Cooler Hose/Pipe Replacement (4WD)»(ref-175731-S22940153652005091200000) .
  10. Remove the transmission oil cooler lines from the radiator. Refer to «TRANSMISSION OIL COOLER LINES»(ref-138559-S00248767832002041700000) .
  11. Remove the radiator bolts.
  12. Remove the radiator from the vehicle.
  1. Install the radiator to the vehicle.
  2. Install the radiator bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. Install the engine oil cooler lines to the radiator. Refer to «Engine Oil Cooler Hose/Pipe Replacement (2WD)»(ref-175731-S19515451392005042600000) or «Engine Oil Cooler Hose/Pipe Replacement (4WD)»(ref-175731-S22940153652005091200000) .
  4. Install the transmission oil cooler lines to the radiator. Refer to «TRANSMISSION OIL COOLER LINES»(ref-138559-S00248767832002041700000) .
  5. Install the radiator vent inlet hose to the radiator.
  6. Reposition the radiator vent inlet hose clamp to the radiator.
  7. Install the lower fan shroud. Refer to «FAN SHROUD REPLACEMENT - Lower»(ref-175731-S28941742142005042600000) .
  8. Install the outlet hose to the radiator.
  9. Reposition the outlet hose clamp to the radiator.
  10. Install the inlet hose to the radiator.
  11. Reposition the inlet hose clamp to the radiator.
  12. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000)
  1. Remove the radiator. Refer to «Radiator Replacement»(ref-175731-S01922609332005042600000)
  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»(ref-175731-S01922609332005042600000) .
  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.

Dealer Installation Only

  1. Drain the cooling system/engine block. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Raise and suitably support the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
  3. Remove the oil pan skid plate bolts and plate.
  4. Remove the oil cooler hose bracket bolt (1).
  5. Remove the oil cooler hose adapter bolts (2).
  6. Remove and discard the oil cooler hose adapter gasket.
  7. Position the oil cooler hose adapter end out of the way.
  8. Install the coolant heater in place of the drain plug. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
  9. Push the engine coolant heater cord electrical connector (2) firmly into the coolant heater (1).
  10. Place the cord into position.
  11. Install the heater cord bolt and retainer. Tighten: Tighten the heater cord bolt to 8 N.m (71 lb in).
  12. Position the oil cooler hose adapter.
  13. Install a NEW oil cooler hose adapter gasket.
  14. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the oil cooler hose adapter bolts to 12 N.m (106 lb in).
  15. Install the oil cooler hose bracket bolt (1). Tighten: Tighten the oil cooler hose bracket bolt to 25 N.m (18 lb ft).
  16. Install the oil pan skid plate and bolts. Tighten: Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).
  17. Lower the vehicle.
  18. Fill the cooling system/engine block. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system/engine block. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  2. Raise and suitably support the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
  3. Remove the oil pan skid plate bolts and plate.
  4. Remove the oil cooler hose bracket bolt (1).
  5. Remove the oil cooler hose adapter bolts (2).
  6. Remove and discard the oil cooler hose adapter gasket.
  7. Position the oil cooler hose adapter end out of the way.
  8. Disconnect the coolant heater electrical connector (2).
  9. Remove the coolant heater from the engine block.
  10. Remove any burrs, sealer, 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. Position the oil cooler hose adapter end.
  5. Install a NEW oil cooler hose adapter gasket.
  6. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the oil cooler hose adapter bolts to 12 N.m (106 lb in).
  7. Install the oil cooler hose bracket bolt (1). Tighten: Tighten the oil cooler hose bracket bolt to 25 N.m (18 lb ft).
  8. Install the oil pan skid plate and bolts. Tighten: Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).
  9. Lower the vehicle.
  10. Fill the cooling system/engine block. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-175731-S33607794312005042600000) .
  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 engine block 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»(ref-175731-S33607794312005042600000) .
  1. Raise and suitably support the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
  2. Disconnect the coolant heater electrical connector (2).
  3. Remove the coolant heater cord retainer and bolts.
  4. Remove the coolant heater cord.

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

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

More articles — Engine Cooling System