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Engine Cooling System: Removal & Installation Chevrolet Tahoe III

Cooling System (Mechanical) 16 illustrations ~4714 words

Removal Procedure

  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  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.

Installation Procedure

  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 «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .

Scheme 3

Scheme 3: Radiator Surge Tank Outlet Hose/Pipe Replacement (HP2)
Scheme 3: Radiator Surge Tank Outlet Hose/Pipe Replacement (HP2)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement . Remove the air cleaner. Refer to Air Cleaner Assembly Replacement . Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Radiator Surge Tank Outlet Hose Quick Disconnect Procedure Squeeze the plastic retainer release tabs and pull the connection apart. The joint should audibly click upon reassembly and the technician should pull back on the joint to ensure it is engaged properly.
2Radiator Surge Tank Outlet Hose Clamp Procedure: Using J 38185 reposition the radiator surge tank outlet hose clamps. See Special Tools . Special Tools: J 38185 Radiator Surge Tank Outlet Hose Clamp. See Special Tools .
3Radiator Surge Tank Outlet Hose Quick Disconnect Procedure Squeeze the plastic retainer release tabs and pull the connection apart. The joint should audibly click upon reassembly and the technician should pull back on the joint to ensure it is engaged properly.
4Radiator Surge Tank Outlet Hose Tip: Radiator surge tank outlet hose and the heater outlet hose are molded as one hose.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  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 (black connector).
  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. Align the arrow at the throttle body end of the duct with the throttle body attaching stud.
  12. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the clamps to 7 N.m (62 lb in).
  13. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .

Scheme 4

Scheme 4: Radiator Inlet Hose Replacement (Non-HP2)
Scheme 4: Radiator Inlet Hose Replacement (Non-HP2)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Radiator Inlet Hose Tip: Remove the radiator vent hose from the radiator inlet hose clips. Using J 38185 reposition the radiator inlet hose clamps. See Special Tools .

Scheme 5

Scheme 5: Radiator Inlet Hose Replacement (HP2)
Scheme 5: Radiator Inlet Hose Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . If necessary, remove the air cleaner resonator duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Radiator Inlet Hose Tip: Remove the radiator vent hose from the radiator inlet hose clips. Using J 38185 reposition the radiator inlet hose clamps. See Special Tools .

Scheme 6

Scheme 6: Radiator Outlet Hose Replacement (HP2)
Scheme 6: Radiator Outlet Hose Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the air cleaner resonator duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove air cleaner housing. Refer to Air Cleaner Assembly Replacement .
1Radiator outlet hose Tip: Using J 38185 reposition the radiator outlet hose clamps. See Special Tools .

Scheme 7

Scheme 7: Radiator Outlet Hose Replacement (Non-HP2)
Scheme 7: Radiator Outlet Hose Replacement (Non-HP2)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Remove air cleaner housing. Refer to Air Cleaner Assembly Replacement
1Radiator Outlet Hose Tip: Using J 38185 reposition the radiator outlet hose clamps. See Special Tools .

Scheme 8

Scheme 8: Radiator Vent Inlet Hose Replacement (Non-HP2)
Scheme 8: Radiator Vent Inlet Hose Replacement (Non-HP2)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . If necessary, remove the air cleaner resonator duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Remove Radiator Vent Inlet Hose Clamp (Qty: 2)
2Remove Radiator Vent Inlet Hose Support Clip (Qty: 2)
3Radiator Vent Inlet Hose

Scheme 9

Scheme 9: Radiator Vent Inlet Hose Replacement (HP2)
Scheme 9: Radiator Vent Inlet Hose Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . If necessary, remove the air cleaner resonator duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Remove radiator vent inlet hose clamp (Qty: 2). Tip: Using J 38185 reposition the radiator vent hose clamps. See Special Tools .
2Radiator vent inlet hose.

Scheme 10

Scheme 10: Engine Oil Cooler Connector Replacement (Radiator)
Scheme 10: Engine Oil Cooler Connector Replacement (Radiator)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) . Remove the engine oil cooler pipe from the oil cooler fittings on the radiator. Refer to Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
1Engine Oil Cooler Fitting CAUTION: Refer to Fastener Caution . Procedure: Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before installation. Tip: Do not remove the upper and lower engine oil cooler fittings from the radiator at the same time other wise the engine oil cooler may fall inside the radiator end tank. The correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness and still leak. Tighten: 24 N.m (18 lb ft)
CAUTION
Refer to Fastener Caution .
  1. Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before installation.
  2. Install the DT-47731 onto the engine oil cooler (EOC) pipe, or use the J 28585
  3. Slide the DT-47731 toward the EOC pipe fitting, or use the J 28585
  4. Connect the DT-47731 onto the EOC pipe fitting.
  5. Rotate the DT-47731 or use the J 28585 until the retainer clip (1) rises above the fitting retainer seat.
  6. Pull back on the EOC pipe to disengage the pipe from the EOC pipe fitting.
  7. Remove the DT-47731 or the J 28585 from the EOC pipe.
  1. Install the EOC pipe into the EOC pipe fitting. A distinct snap should be heard or felt when assembling the EOC pipe to the fitting.
  2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull.

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 Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-364492-S08446493292010063000000) .
  2. If equipped with regular production option (RPO) L76 (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-364496-S07186948972010063000000) .
  4. If equipped with RPO LY6 (6.0L) engine, remove the oil cooler hoses from the clip.
  5. Place a jack or utility stands at the rear of the vehicle.
  6. If equipped, remove the engine protection shield. Refer to «Engine Shield Replacement»(ref-364494-S23909670222010063000000) .
  7. If equipped, remove the front differential carrier shield. Refer to «Shield Replacement»(ref-364564-S03993895022010063000000) .
  8. For both 1500 and 2500 series, support the front differential carrier with a suitable adjustable jack.
  9. For 1500 series vehicles, remove the differential carrier right side nuts.
  10. Remove the differential carrier left side bolts.
  11. Lower the differential carrier.
  12. For 2500 series vehicles, remove the differential carrier right side nuts.
  13. Remove the differential carrier upper mounting bolt and nut.
  14. Remove the differential carrier lower mounting bolt and nut.
  15. If equipped with RPO L76 (6.0L) engine, perform the following: Lower the differential carrier. 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 RPO LY6 (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. Discard the gasket. Inspect the fittings, connectors, and cooler hoses for damage or distortion.
  1. If equipped with RPO LY6 (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. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  2. If equipped with a RPO L76 (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. For 2500 series vehicles, raise the differential carrier into position.
  4. Install the differential carrier left side upper bolt and nut until snug.
  5. Install the differential carrier left side lower bolt and nut until snug.
  6. Install the differential carrier right side nuts. Tighten: Tighten the bolt to 100 N.m (74 lb ft).
  7. For 1500 series vehicles, raise the differential carrier into position.
  8. Install the differential carrier right side nuts.
  9. Install the differential carrier left side bolts. Tighten: Tighten the bolts/nuts to 100 N.m (74 lb ft).
  10. If equipped, install the engine protection shield. Refer to «Engine Shield Replacement»(ref-364494-S23909670222010063000000) .
  11. Remove the jack or utility stand from the rear of the vehicle.
  12. Lower the vehicle.
  13. If equipped with RPO LY6 (6.0L) engine, install the oil cooler hoses to the clip.
  14. If equipped with RPO L76 (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.
  15. Install the oil cooler lines to the radiator. Refer to «Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-364492-S08446493292010063000000) .

Fan Replacement (Mechanical)

Special Tools

  1. J 41240-5A Fan Clutch Wrench. See «Special Tools»(ref-364492-S13195046632010063000000) .
  2. J-48460 Fan Clutch Remover and Installer Kit. See «Special Tools»(ref-364492-S13195046632010063000000) .
  1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Mechanical)»(ref-364492-S24575716452010063000000) .
  2. Install the J-48460 Fan Clutch Remover and Installer Kit (1). See «Special Tools»(ref-364492-S13195046632010063000000) .
  3. Install the J 41240-5A Fan Clutch Wrench (2). See «Special Tools»(ref-364492-S13195046632010063000000) .
  4. Remove the fan hub nut from the water pump in a counterclockwise rotation.
  5. Remove the fan clutch bolts from the rear of the fan blade.
  6. Separate the fan clutch from the fan blade.
WARNINGDo 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-48460 Fan Clutch Remover and Installer Kit (1) and J 41240-5A Fan Clutch wrench (2). See «Special Tools»(ref-364492-S13195046632010063000000) . 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 (Mechanical)»(ref-364492-S24575716452010063000000) .

Scheme 11

Scheme 11: Engine Coolant Fan Replacement (HP2)
Scheme 11: Engine Coolant Fan Replacement (HP2)
CalloutComponent Name
Preliminary Procedures: Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (HP2)
1Cooling fan blade retainers (Qty: 2)
2Cooling fan blades.
  1. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement (Non-HP2)»(ref-364492-S36139308092010063000000) .
  2. Remove the cooling fan blade retainers.
  3. Remove the cooling fan blades.

Note. The 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 (Non-HP2)»(ref-364492-S36139308092010063000000) .

Scheme 12

Scheme 12: Engine Coolant Fan Motor Replacement (HP2)
Scheme 12: Engine Coolant Fan Motor Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Remove the cooling blade(s). Refer to Engine Coolant Fan Replacement (HP2) Disconnect the electrical connectors from the cooling fans.
1Cooling Fan Motor Bolts (Qty: 6) CAUTION: Refer to Fastener Caution . Tighten: 10 N.m (89 lb in)
2Cooling Fan Motor(s).
CAUTION
Refer to Fastener Caution .
  1. Remove the cooling blade(s). Refer to «Engine Coolant Fan Replacement (Non-HP2)»(ref-364492-S28221606882010063000000) .
  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 blades. Refer to «Engine Coolant Fan Replacement (Non-HP2)»(ref-364492-S28221606882010063000000) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000)
  2. Remove air inlet duct.
  3. Disconnect upper radiator hose from radiator.
  4. Disengage the radiator inlet hose clip (2) at the fan shroud.
  5. If necessary, reposition the surge tank inlet hose clamp at the radiator.
  6. If necessary, remove the surge tank inlet hose from the radiator.
  7. Disconnect the electrical connectors from the cooling fans.
  8. Remove the clip attaching the wiring harness to the shroud.
  9. Remove transmission cooler lines bolts from fan shroud.
  10. If necessary, open the engine oil cooler line clip and remove the cooler lines from the clip.
  11. Remove the cooling fan shroud bolts.
  12. 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 transmission cooling line bolts to fan shroud. Tighten: Tighten the bolts to 4 N.m (35 lb in).
  7. If necessary, install the surge tank inlet hose to the radiator.
  8. If necessary, reposition the surge tank inlet hose clamp at the radiator.
  9. Engage the radiator inlet hose clip (2) at the fan shroud.
  10. Connect upper radiator hose from radiator.
  11. Install air inlet duct.
  12. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000)

Scheme 13

Scheme 13: Cooling Fan and Shroud Replacement (HP2)
Scheme 13: Cooling Fan and Shroud Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Remove the radiator air upper baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) . Remove air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement . Reposition radiator vent hose. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement (HP2) . Disconnect engine coolant fan electrical connectors. Disconnect engine coolant fan resistor electrical connectors. Remove the generator control module coolant pump hose (pump to radiator). Refer to Generator Control Module Coolant Pump Hose Replacement (Pump to Pump) or Generator Control Module Coolant Pump Hose Replacement (Pump to Radiator) . Remove the generator control module coolant outlet hose. Refer to Generator Control Module Coolant Outlet Hose Replacement . Remove the trans cooler line clip from right side of shroud.
1Cooling Fan Shroud Bolt (Qty: 2)
2Cooling Fan Shroud Tip: Lift cooling fan and shroud in and upward. Transfer parts as required.

Scheme 14

Scheme 14: Engine Coolant Fan Resistor Replacement (Right HP2)
Scheme 14: Engine Coolant Fan Resistor Replacement (Right HP2)
CalloutComponent Name
Preliminary Procedures Remove air cleaner. Refer to Air Cleaner Assembly Replacement Disconnect the electrical connector from the resistor.
1Engine Coolant Fan Resistor Bolt CAUTION: Refer to Fastener Caution . Tighten: 10 N.m (89 lb in)
2Engine Coolant Fan Resistor
CAUTION
Refer to Fastener Caution .

Scheme 15

Scheme 15: Engine Coolant Fan Resistor Replacement (Left HP2)
Scheme 15: Engine Coolant Fan Resistor Replacement (Left HP2)
CalloutComponent Name
Preliminary Procedures: Disconnect the electrical connector from the resistor.
1Engine Coolant Fan Resistor Bolt CAUTION: Refer to Fastener Caution . Tighten: 10 N.m (89 lb in)
2Engine Coolant Fan Resistor
CAUTION
Refer to Fastener Caution .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  3. Reposition the radiator outlet hose clamp at the water pump inlet.
  4. Remove the radiator outlet hose from the water pump inlet.
  5. Remove the water pump inlet bolts (1).
  6. Remove the water pump inlet from the water pump.
  7. Remove and discard the water pump inlet seal.
  1. Install a NEW water pump inlet seal to the water pump inlet.
  2. Position the water pump inlet to the water pump.
  3. Install the water pump inlet bolts (1) and tighten to 15 N.m (11 lb ft).
  4. Install the radiator outlet hose to the water pump inlet.
  5. Position the radiator outlet hose clamp at the water pump inlet.
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  1. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6)»(ref-364492-S15562140282010063000000) .
  2. Remove the thermostat.
  1. Install the thermostat.
  2. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6)»(ref-364492-S15562140282010063000000) .
  1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to «Intake Manifold Replacement (Without AFM)»(ref-364523-S07226539562010063000000) . Otherwise proceed to the next step.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  3. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting.
  5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
  6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity).
  7. Remove the coolant air bleed pipe (307) and seals (308).
  8. Remove the coolant air bleed cover bolts (312), if required.
  9. Remove the coolant air bleed covers (313) and seals (308), if required.
  10. Remove the seals (308) from the coolant air bleed pipe and/or covers.
  11. Discard the seals.
  1. Install the seals onto the coolant air bleed pipe and/or covers.
  2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads.
  3. Install the coolant air bleed pipe bolts (309) and tighten to 12 N.m (106 lb in).
  4. Install the coolant air bleed covers (313) and seals (308), if required.
  5. If required, install the coolant air bleed cover bolts (312) and tighten to 12 N.m (106 lb in).
  6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting.
  7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting.
  8. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to «Intake Manifold Replacement (With AFM)»(ref-364523-S18673506622010063000000) .
  1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to «Intake Manifold Replacement (With AFM)»(ref-364523-S18673506622010063000000) . Otherwise proceed to the next step.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  3. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting.
  5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
  6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity).
  7. Remove the coolant air bleed pipe (307) and seals (308).
  8. Remove the coolant air bleed cover bolts (312), if required.
  9. Remove the coolant air bleed covers (313) and seals (308), if required.
  10. Remove the seals (308) from the coolant air bleed pipe and/or covers.
  11. Discard the seals.
  1. Install the seals onto the coolant air bleed pipe and/or covers.
  2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads.
  3. Install the coolant air bleed pipe bolts (309) and tighten to 12 N.m (106 lb in).
  4. Install the coolant air bleed covers (313) and seals (308), if required.
  5. If required, install the coolant air bleed cover bolts (312) 12 N.m (106 lb in).
  6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting.
  7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting.
  8. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to «Intake Manifold Replacement (With AFM)»(ref-364523-S18673506622010063000000) .
  1. If necessary, remove the engine sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(ref-364523-S11798492912010063000000) for the 4.8L, 5.3L, and 6.0L engines.
  2. Position the coolant air bleed hose clamp at the throttle body.
  3. Remove the coolant air bleed hose from the throttle body.
  4. Position 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 «Upper Intake Manifold Sight Shield Replacement»(ref-364523-S11798492912010063000000) for the 4.8L, 5.3L, and 6.0L engines.
  6. Add engine coolant, if necessary.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  2. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting.
  4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting.
  5. Reposition the radiator inlet hose clamp (3) at the water pump.
  6. Remove the radiator inlet hose from the water pump.
  7. Reposition the radiator inlet hose and vent inlet hose out of the way.
  8. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-364523-S09180508032010063000000) .
  9. Reposition the radiator outlet hose clamp at the water pump.
  10. Remove the radiator outlet hose from the water pump.
  11. Reposition the outlet hose out of the way.
  12. Reposition the radiator surge tank outlet hose clamp at the water pump (1).
  13. Remove the radiator surge tank outlet hose (2) from the water pump.
  14. Reposition the outlet hose out of the way.
  15. Reposition the heater inlet hose clamp (1) at the water pump.
  16. Remove the heater inlet hose (2) from the water pump.
  17. Reposition the inlet hose out of the way.
  18. Remove the water pump bolts (301).
  19. Remove the water pump (300) and gaskets (309). Discard the gaskets.
CAUTIONDO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly.

Note. All gaskets surfaces are to be free of oil or other foreign material during assembly.

  1. Inspect the drained coolant for sand or other debris, flush the system as needed. Refer to «Flushing»(ref-364492-S25696332992010063000000) .
  2. Inspect and clear the radiator vent hose fitting, if necessary. There is a small 2.0 mm (0.080 in) orifice (vent hose fitting) in the neck of the radiator where the coolant vent hose from the engine attaches to the radiator.
  3. Position the water pump (300) and NEW gaskets (306) to the engine block.
  4. Install the water pump bolts (301). 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).
  5. Position and install the heater inlet hose (2) to the water pump.
  6. Position the heater inlet hose clamp (1) at the water pump.
  7. Position and install the radiator surge tank outlet hose (2) to the water pump.
  8. Position the radiator surge tank outlet hose clamp at the water pump (1).
  9. Position and install the radiator outlet hose to the water pump.
  10. Position the radiator outlet hose clamp at the water pump.
  11. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-364523-S09180508032010063000000) .
  12. Position the radiator inlet hose and vent inlet hose to the correct position.
  13. Install the radiator inlet hose to the water pump.
  14. Position the radiator inlet hose clamp (3) at the water pump.
  15. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting.
  16. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting.
  17. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  18. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-364495-S39273193582010063000000) .
  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 (2).
  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 (2). Tighten: Tighten the clamp to 4 N.m (35 lb in).
  1. Remove the radiator. Refer to «Radiator Replacement (HP2)»(ref-364492-S34547606852010063000000) .
  2. Disengage the two clips from the radiator.
  3. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud.
  4. Remove the shroud from the vehicle.
  1. Install the lower fan shroud and ensure it is centered over lower radiator support.
  2. Engage the two clips from the radiator.
  3. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud.
  4. Install the radiator. Refer to «Radiator Replacement (HP2)»(ref-364492-S34547606852010063000000) .

Scheme 16

Scheme 16: Radiator Replacement (HP2)
Scheme 16: Radiator Replacement (HP2)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Remove air cleaner assembly. Refer to Air Cleaner Assembly Replacement Remove radiator air upper baffel and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Yukon) or Radiator Air Upper Baffle and Deflector Replacement (Cadillac) Remove radiator surge tank. Refer to Radiator Surge Tank Replacement (HP2) Remove radiator surge tank inlet hose/pipe. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (HP2) Remove radiator vent inlet hose. Refer to Radiator Vent Inlet Hose Replacement (HP2) Remove radiator hose inlet. Refer to Radiator Inlet Hose Replacement (HP2) Remove radiator hose outlet. Refer to Radiator Outlet Hose Replacement (HP2) Remove cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (HP2) Remove the generator control module coolant radiator. Refer to Generator Control Module Coolant Radiator Replacement
1Radiator Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 25 N.m (18 lb ft)
2Radiator Assembly
CAUTION
Refer to Fastener Caution .

Scheme 17

Scheme 17: Radiator Air Upper Baffle and Deflector Replacement (Yukon)
Scheme 17: Radiator Air Upper Baffle and Deflector Replacement (Yukon)
CalloutComponent Name
1Radiator Air Baffle Pushpin Fastener (Qty: 4)
2Radiator Air Upper Baffle

Scheme 18

Scheme 18: Radiator Air Upper Baffle and Deflector Replacement (Cadillac)
Scheme 18: Radiator Air Upper Baffle and Deflector Replacement (Cadillac)
CalloutComponent Name
1Radiator Air Baffle Pushpin Fastener (Qty: 9)
2Radiator Air Upper Baffle
  1. Drain the cooling system/engine block. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  3. Remove the oil pan skid plate bolts and plate, if equipped.
  4. For vehicles with regular production option (RPO) L76 (6.0L), perform the following steps. Otherwise, proceed to step 9.
  5. Remove the oil cooler hose bracket bolt (1), if equipped.
  6. Remove the oil cooler hose adapter bolts (2), if equipped.
  7. Remove and discard the oil cooler hose adapter gasket, if equipped.
  8. Position the oil cooler hose adapter end out of the way, if equipped.
  9. Disconnect the coolant heater cord electrical connector.
  10. Remove the coolant heater from the engine block.
  11. 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 and tighten to 50 N.m (37 lb ft).
  3. Connect the coolant heater cord electrical connector.
  4. For vehicles with RPO L76 (6.0L) perform the following steps otherwise proceed to step 9.
  5. Position the oil cooler hose adapter end, if equipped.
  6. Install a NEW oil cooler hose adapter gasket, if equipped.
  7. If equipped, install the oil cooler hose adapter bolts (2) And tighten to 12 N.m (106 lb in).
  8. If equipped, install the oil cooler hose bracket bolt (1) and tighten to 25 N.m (18 lb ft).
  9. If equipped, position and install the oil pan skid plate and bolts and tighten to 20 N.m (15 lb ft)
  10. Lower the vehicle.
  11. Fill the cooling system/engine block. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  1. Drain the cooling system/engine block. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  3. For 1500 series vehicles, remove the oil pan skid plate bolts and plate, if equipped.
  4. For 2500 series vehicle, remove the front 2 oil pan skid plate bolts, loosen the 2 rear bolts and remove the skid plate, if equipped.
  5. For vehicles with regular production option (RPO) LY6 (6.0L) perform the following steps otherwise proceed to step 10.
  6. Remove the oil cooler hose bracket bolt (1).
  7. Remove the oil cooler hose adapter bolts (2).
  8. Remove and discard the oil cooler hose adapter gasket.
  9. Reposition the oil cooler hose adapter end out of the way.
  10. Disconnect the coolant heater cord electrical connector.
  11. Remove the coolant heater from the engine block.
  12. 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 and tighten to 50 N.m (37 lb ft).
  3. Connect the coolant heater cord electrical connector.
  4. For vehicles with RPO LY6 (6.0L) perform the following steps otherwise proceed to step 9.
  5. Position the oil cooler hose adapter end.
  6. Install a NEW oil cooler hose adapter gasket.
  7. Install the oil cooler hose adapter bolts (2) and tighten to 12 N.m (106 lb in).
  8. Install the oil cooler hose bracket bolt (1) and tighten to 25 N.m (18 lb ft).
  9. If equipped, for 2500 series vehicles, position the oil pan skid plate and install the 2 front bolts and tighten the 2 rear bolts and tighten to 20 N.m (15 lb ft)
  10. If equipped, for 1500 series vehicles position and install the oil pan skid plate and bolts and tighten to 20 N.m (15 lb ft).
  11. Lower the vehicle.
  12. Fill the cooling system/engine block. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-364492-S20837984752010063000000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  2. Remove the oil pan skid plate bolts and plate, if equipped.
  3. Disconnect the coolant heater cord electrical connector.
  4. Remove the coolant heater cord retainer (5) from the frame.
  5. Remove the coolant heater cord clip (6) from the front brake front pipe.
  6. Lower the vehicle.
  7. Remove the coolant heater cord bolt (4) from the frame.
  8. Remove the coolant heater cord clip (2) from the chassis harness.
  9. Remove the coolant heater cord clip (1) from the front spring stud.
  10. Remove the coolant heater cord from the vehicle.
  1. Install the coolant heater cord to the vehicle.
  2. Install the coolant heater cord clip (1) to the front spring stud.
  3. Install the coolant heater cord clip (2) to the chassis harness.
  4. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt (4) and tighten to 8 N.m (71 lb in).
  5. Raise the vehicle.
  6. Install the coolant heater cord clip (6) to the front brake front pipe.
  7. Position the coolant heater cord clip to the frame and install the coolant heater cord retainer (5).
  8. Connect the coolant heater cord electrical connector.
  9. If equipped, position and install the oil pan skid plate and bolts and tighten to 20 N.m (15 lb ft).
  10. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  2. Remove the oil pan skid plate bolts and plate, if equipped.
  3. Disconnect the coolant heater cord electrical connector.
  4. Remove the coolant heater cord clip (3) from the engine harness channel.
  5. Remove the coolant heater cord clip (1) from the power steering gear outlet hose.
  6. Lower the vehicle.
  7. Remove the coolant heater cord bolt (2) from the frame.
  8. Remove the coolant heater cord from the vehicle.
  1. Install the coolant heater cord to the vehicle.
  2. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt (2) and tighten to 8 N.m (71 lb in).
  3. Raise the vehicle.
  4. Install the coolant heater cord clip (1) to the power steering gear outlet hose.
  5. Install the coolant heater cord clip (3) to the engine harness channel.
  6. Connect the coolant heater cord electrical connector.
  7. If equipped position and install the oil pan skid plate and boltsand tighten to 20 N.m (15 lb ft).
  8. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-364496-S07186948972010063000000) .
  2. Remove the front 2 oil pan skid plate bolts, loosen the 2 rear bolts and remove the skid plate, if equipped.
  3. Disconnect the coolant heater cord electrical connector.
  4. Remove the coolant heater cord clip (1) from the front brake front pipes.
  5. Remove the coolant heater cord clip retainer (2) from the frame.
  6. Lower the vehicle.
  7. Remove the coolant heater cord bolt (3) from the frame.
  8. Remove the coolant heater cord from the vehicle.
  1. Install the coolant heater cord to the vehicle.
  2. Position the coolant heater cord clip to the frame and install the coolant heater cord bolt (3) and tighten to 8 N.m (71 lb in).
  3. Raise the vehicle.
  4. Install the coolant heater cord clip retainer (2) to the frame.
  5. Install the coolant heater cord clip (1) to the front brake front pipes.
  6. Connect the coolant heater cord electrical connector.
  7. If equipped, position the oil pan skid plate and install the 2 front bolts and tighten the 2 rear bolts and tighten to 20 N.m (15 lb ft).
  8. Lower the vehicle.

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