Engine Cooling System: Removal & Installation Chevrolet TrailBlazer I

Radiator Hose Replacement - Inlet (Body Vin Code 3)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 42

Scheme 43

1. Drain the coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Reposition the inlet radiator hose clamp at the thermostat (1) using J 38185 .
3. Remove the inlet radiator hose from the thermostat.
4. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
5. Remove the lower radiator support shield, if equipped.
6. Reposition the inlet radiator hose clamp at the radiator using J 38185 .
7. Remove the inlet radiator hose (1) from the radiator.

Scheme 44

Scheme 45

1. Install the inlet radiator hose clamps to the radiator hose (1).
2. Install the inlet radiator hose (1) to the radiator.
3. Reposition the inlet radiator hose clamp using J 38185 .
4. Install the lower radiator support shield, if equipped.
5. Lower the vehicle.
6. Install the inlet radiator hose to the thermostat (1).
7. Reposition the inlet radiator hose using J 38185 .
8. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Hose Replacement - Inlet (Body Vin Code 6 LM4)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 46

Scheme 47

1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
3. Reposition the inlet radiator hose clamp (3) using J 38185 .
4. Remove the inlet radiator hose (2) from the radiator (1).
5. Reposition the inlet radiator hose clamp (3) using J 38185 .
6. Remove the radiator inlet hose from the engine (5).
7. Remove the radiator inlet hose.

Scheme 48

Scheme 49

1. Install the radiator inlet hose to the engine (5).
2. Reposition the inlet radiator hose clamp (3).
3. Install the inlet radiator hose (2) to the radiator (1).
4. Reposition the inlet radiator hose clamp (3).
5. Lower the vehicle.
6. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Hose Replacement - Inlet (Body Vin Code 6 LL8)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 50

Scheme 51

1. Drain the coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Reposition the inlet radiator hose clamp at the thermostat (1) using J 38185 .
3. Remove the inlet radiator hose from the thermostat.
4. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
5. Remove the lower radiator support shield, if equipped.
6. Reposition the inlet radiator hose clamp at the radiator using J 38185 .
7. Remove the inlet radiator hose (1) from the radiator.

Scheme 52

Scheme 53

1. Install the inlet radiator hose clamps to the radiator hose (1).
2. Install the inlet radiator hose (1) to the radiator.
3. Reposition the inlet radiator hose clamp using J 38185 .
4. Install the lower radiator support shield, if equipped.
5. Lower the vehicle.
6. Install the inlet radiator hose to the thermostat (1).
7. Reposition the inlet radiator hose using J 38185 .
8. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Hose Replacement - Outlet (Body Vin Code 3)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 54

1. Drain the engine coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185 .
3. Remove the inlet radiator hose from the radiator.
4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J 38185 .
5. Remove the inlet radiator hose from the engine.

Scheme 55

1. Install the inlet radiator hose clamps (1, 2) to the radiator hose.
2. Install the inlet radiator hose to the engine.
3. Reposition the inlet radiator hose clamp (1) using J 38185 .
4. Install the inlet radiator hose to the radiator.
5. Reposition the inlet radiator hose clamp (2) using J 38185 .
6. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Hose Replacement - Outlet (Body Vin Code 6 LM4)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 56

Scheme 57

1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Remove the air intake resonator. Refer to «AIR CLEANER RESONATOR OUTLET DUCT»(ref-159085-S05754353602003111400000) .
3. Reposition the outlet hose clamp from the water pump.
4. Remove the outlet hose from the water pump.
5. Reposition the outlet hose clamp from the radiator.
6. Remove the outlet hose from the radiator.

Scheme 58

Scheme 59

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 intake resonator. Refer to «AIR CLEANER RESONATOR OUTLET DUCT»(ref-159085-S05754353602003111400000) .
6. Install the radiator inlet hose clip to the outlet duct.
7. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Hose Replacement - Outlet (Body Vin Code 6 LL8)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 60

1. Drain the engine coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185 .
3. Remove the inlet radiator hose from the radiator.
4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J 38185 .
5. Remove the inlet radiator hose from the engine.

Scheme 61

1. Install the inlet radiator hose clamps (1, 2) to the radiator hose.
2. Install the inlet radiator hose to the engine.
3. Reposition the inlet radiator hose clamp (1) using J 38185 .
4. Install the inlet radiator hose to the radiator.
5. Reposition the inlet radiator hose clamp (2) using J 38185 .
6. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Removal Procedure

1. Partially drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Remove the upper radiator baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.
3. Remove the vent inlet hose from the radiator.
4. Remove the vent inlet hose from the surge tank.

Installation Procedure

1. Install the vent inlet hose to the surge tank.
2. Install the vent inlet hose to the radiator.
3. Install the upper radiator baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.
4. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

1. Remove the cooling fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
2. Remove the bolts retaining the fan blade to the fan clutch.
3. Separate the fan blade from the fan clutch.

1. Assemble the fan to the fan clutch. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the 4 bolts to the fan blade and tighten. Tighten Tighten the bolts to 27 N.m (20 lb ft).
3. Install the cooling fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .

Cooling Fan and Shroud Replacement

Tools Required

J 41240 Fan Clutch Remover and Installer

J 38185 Hose Clamp Pliers

Scheme 62

Scheme 63

Scheme 64

1. Remove the air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.
2. Remove the hood latch support. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
3. Disconnect the transmission cooler lines at the engine and release the lines from the fan shroud.
4. Remove the 2 upper bolts on the fan shroud.
5. Reposition the upper inlet radiator hose clamp using J 38185 .
6. Remove the upper inlet radiator hose from the radiator.
7. Remove the electrical connector from the shroud.
8. Position the water pump so the bolts are aligned in the vertical.
9. Remove the fan hub nut from the water pump shaft in a counterclockwise rotation. Using the J 46406 , in order to secure the water pump pulley, loosen the cooling fan hub nut from the water pump shaft.
10. Unclip the fan shroud from the radiator at the side panels (1).
11. Tilt the radiator and the condenser forward.
12. Lift the fan and the shroud up and out towards the engine to release the fan from the radiator to clear the radiator inlet.

Scheme 65

Scheme 66

Scheme 67

1. Install the fan and the shroud onto the lip of the radiator bottom. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the 2 bolts into the upper fan shroud and tighten. Tighten Tighten the bolts to 28 N.m (21 lb ft).
3. Connect the electrical connector.
4. Clip the fan shroud to the radiator at the side panels (1).
5. Using the J 46406 to secure the water pump pulley, install the fan nut to the water pump shaft in a clockwise rotation. Tighten Tighten the fan hub nut to 56 N.m (41 lb ft).
6. Install the transmission cooler lines to the engine and clip into the fan shroud.
7. Install the hood latch support. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
8. Install the upper inlet radiator hose to the radiator.
9. Reposition the upper inlet radiator hose clamp using J 38185 .
10. Install the air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.

Cooling Fan Relay Replacement

Tools Required

J 43244 Relay Puller Pliers

Scheme 68

1. Remove the underhood electrical center cover.
2. Using the J 43244 , remove the cooling fan relay (3).

Note. Installation of the proper relay is critical. If an enhanced relay - equipped with a diode - is installed into a position requiring a standard relay - equipped without a diode - excessive current will damage any components associated with the relay or its associated circuits.

Scheme 69

1. Install the cooling fan relay (3).
2. Install the underhood electrical center cover.

Thermostat Replacement (4.2L Engine)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 70

Scheme 71

1. Remove the necessary coolant from the radiator. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Remove the generator. Refer to GENERATOR REPLACEMENT (4.2L ENGINE) or GENERATOR REPLACEMENT (5.3L ENGINE) in Engine Electrical
3. Loosen the outlet hose clamp at the water inlet (1) of the thermostat. Remove the outlet hose from the water inlet.
4. Remove the thermostat housing at the water inlet bolts.
5. Remove the thermostat housing from the engine block.
6. Clean all of the surfaces of the thermostat housing.
7. Clean the sealing surface of the engine block.

Scheme 72

Scheme 73

1. Install the thermostat housing at the water inlet to the engine block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the thermostat housing bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
3. Lubricate the inner diameter of the radiator hose with engine coolant.
4. Install the outlet hose to the thermostat (1). Secure the hose with the clamp.
5. Install the generator. Refer to GENERATOR REPLACEMENT (4.2L ENGINE) or GENERATOR REPLACEMENT (5.3L ENGINE) in Engine Electrical
6. Fill the cooling system with specified coolant and concentration. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
7. Inspect all sealing surfaces for leaks after starting the engine.

Scheme 74

1. Remove the radiator outlet hose. Refer to «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 3)»(ref-188500-S05620750492005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LM4)»(ref-188500-S33099071302005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LL8)»(ref-188500-S08048614972005090300000) .
2. Remove the water pump inlet bolts.
3. Remove the water pump inlet and thermostat from the water pump.

Scheme 75

1. Install the thermostat and thermostat housing to the water pump. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the thermostat housing bolts. Tighten Tighten the bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose. Refer to «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 3)»(ref-188500-S05620750492005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LM4)»(ref-188500-S33099071302005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LL8)»(ref-188500-S08048614972005090300000) .

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Remove the coolant air bleed pipe bolts (2).
2. Remove the coolant air bleed pipe (1) with gaskets.
3. Remove the coolant air bleed pipe cover bolts (1) and covers (2).
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).

Scheme 80

Scheme 81

Scheme 82

Scheme 83

1. Install the coolant air bleed hose (1) onto the pipe (2). IMPORTANT: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe.
2. Install the gaskets onto the coolant air bleed pipe and covers.
3. Install the coolant air bleed pipe (1) and gaskets onto the cylinder heads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the coolant air bleed pipe bolts (2). 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).

Scheme 84

Scheme 85

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).

Scheme 86

Scheme 87

1. Install the coolant air bleed hose (1) to the pipe (2).
2. Position the coolant air bleed hose clamp at the pipe.
3. Install the coolant air bleed hose to the throttle body.
4. Position the coolant air bleed hose clamp at the throttle body.
5. Add engine coolant, if necessary.

Scheme 88

1. Disconnect the outlet radiator hose from the water outlet housing. Refer to «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 3)»(ref-188500-S05620750492005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LM4)»(ref-188500-S33099071302005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LL8)»(ref-188500-S08048614972005090300000) .
2. Remove the power steering pump bracket. Refer to POWER STEERING PUMP BRACKET REPLACEMENT in Power Steering System.
3. Remove the water outlet bolts.
4. Remove the water outlet.

Scheme 89

1. Install the water outlet. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the water outlet bolts. Tighten Tighten the water outlet bolts to 10 N.m (89 lb in).
3. Connect the outlet radiator hose to the water outlet housing. Refer to «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 3)»(ref-188500-S05620750492005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LM4)»(ref-188500-S33099071302005090300000) or «RADIATOR HOSE REPLACEMENT - OUTLET (BODY VIN CODE 6 LL8)»(ref-188500-S08048614972005090300000) .
4. Install the power steering pump bracket. Refer to POWER STEERING PUMP BRACKET REPLACEMENT in Power Steering System.

Water Pump Replacement (4.2L Engine)

Tools Required

J 41240 Fan Clutch Wrench

Scheme 90

Scheme 91

1. Drain the coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Remove the fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
3. Remove the drive belt. Refer to DRIVE BELT REPLACEMENT in Engine Mechanical - 4.2L.
4. Using the J 41240 , secure the water pump pulley and remove the water pump pulley bolts.
5. Remove the J 41240 .
6. Remove the water pump pulley.
7. Loosen and remove the water pump bolts.
8. Remove the water pump.
9. Clean and inspect the water pump. Refer to «WATER PUMP CLEANING AND INSPECTION»(ref-188499-S24805382522005090700000) .
10. Discard and replace the gasket.

Scheme 92

Scheme 93

1. Install a new water pump gasket. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the water pump and secure the water pump with the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
3. Install the water pump pulley.
4. Install the water pump pulley bolts.
5. Using the J 41240 , secure the water pump pulley while tightening the water pump pulley bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
6. Remove the J 41240 .
7. Install the drive belt. Refer to DRIVE BELT REPLACEMENT in Engine Mechanical - 4.2L.
8. Install the fan and the shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
9. Fill the cooling system with the specified coolant and concentration. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
10. Inspect for leaks.

Water Pump Replacement (5.3L Engine)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
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 bolt and duct.
4. Remove the accessory drive belt. Refer to DRIVE BELT REPLACEMENT - ACCESSORY in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
5. Remove the cooing fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
6. Using J 38185 , reposition the inlet hose clamp at the water pump.
7. Remove the inlet hose from the water pump.
8. Using J 38185 , reposition the outlet hose clamp at the water pump.
9. Remove the outlet hose from the water pump.
10. Remove the auxiliary heater inlet and outlet hose/pipe nut.
11. Using J 38185 , reposition the throttle body hose clamp at the throttle body.
12. Remove the hose from the throttle body.
13. Using J 38185 , reposition the auxiliary heater inlet and outlet hose/pipe clamps at the water pump.
14. Remove the inlet and outlet hoses/pipes from the water pump.
15. Disconnect the auxiliary heater inlet and outlet hoses/pipes from the heater water shutoff valve.
16. Remove the auxiliary heater inlet and outlet hoses/pipes.
17. Remove the water pump bolts.
18. Remove the water pump and gaskets.
19. Discard the water pump gaskets.

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

1. Install the water pump and NEW gaskets. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the water pump bolts. Tighten 2.1. Tighten the bolts a first pass to 15 N.m (11 lb ft). 2.2. Tighten the bolts a final pass to 30 N.m (22 lb ft).
3. Install the auxiliary heater inlet and outlet hoses/pipes.
4. Connect the auxiliary heater inlet and outlet hoses/pipes to the heater water shutoff valve.
5. Install the auxiliary heater inlet and outlet hose/pipe nut. Tighten Tighten the nut to 10 N.m (89 lb in).
6. Install the hose to the throttle body.
7. Using J 38185 , position the throttle body hose clamp at the throttle body.
8. Install the inlet and outlet hoses/pipes to the water pump.
9. Using J 38185 , position the auxiliary heater inlet and outlet hose/pipe clamps at the water pump.
10. Install the outlet hose to the water pump.
11. Using J 38185 , position the outlet hose clamp at the water pump.
12. Install the inlet hose to the water pump.
13. Using J 38185 , position the inlet hose clamp at the water pump.
14. Install the cooing fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
15. Install the accessory drive belt. Refer to DRIVE BELT REPLACEMENT - ACCESSORY in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
16. Install the air cleaner outlet duct and bolt. Tighten Tighten the bolt to 10 N.m (89 lb in).
17. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten Tighten the clamps to 7 N.m (62 lb in).
18. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Replacement (Body Vin Code 6)

Tools Required

J 41240 Fan Clutch Wrench

J 38185 Hose Clamp Pliers

Scheme 106

Scheme 107

1. Drain the coolant from the radiator. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Remove the lower radiator support shield, if equipped.
3. Remove the transmission cooler lines from the radiator. Refer to «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000) .
4. Reposition the outlet radiator hose clamp using J 38185 .
5. Remove the outlet radiator hose from the radiator.
6. Lower the vehicle.
7. Remove the cooling fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
8. Remove the grille. Refer to AIR INLET GRILLE PANEL REPLACEMENT in Body Front End.
9. Remove the upper radiator to condenser bolts.
10. Remove the coolant recovery line from the radiator.
11. Lift upward on the condenser to remove from the radiator retaining tab.
12. Remove the radiator.

Scheme 108

Scheme 109

Scheme 110

1. Install the radiator.
2. Install the condenser to the radiator retaining tab.
3. Install the coolant recovery line to the radiator. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
4. Install the bolts retaining the condenser to the radiator. Tighten Tighten the bolts to 28 N.m (21 lb ft).
5. Install the grille. Refer to AIR INLET GRILLE PANEL REPLACEMENT in Body Front End.
6. Install the cooling fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
7. Raise the vehicle.
8. Install the outlet radiator hose (1) to the radiator.
9. Reposition the outlet radiator hose clamp (1) using J 38185 .
10. Connect the transmission cooler lines to the radiator. Refer to «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000) .
11. Install the lower radiator support shield, if equipped.
12. Lower the vehicle.
13. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Radiator Replacement (Body Vin Type 3)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 111

Scheme 112

Scheme 113

1. Drain the coolant from the radiator. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
3. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
4. Remove the lower radiator support shield, if equipped.
5. Reposition the outlet radiator hose clamp using J 38185 .
6. Remove the outlet radiator hose (1) from the radiator.
7. Remove the transmission cooler lines from the radiator. Refer to «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000) .
8. Lower the vehicle.
9. Remove the cooling fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
10. Remove the radiator support diagonal brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
11. Remove the coolant recovery line from the radiator.
12. Disconnect the radiator side panels from the shroud (1).
13. Remove the radiator.
14. Remove the bolts retaining the condenser to the radiator.

Scheme 114

Scheme 115

Scheme 116

1. Install the condenser to the radiator. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the bolts retaining the condenser to the radiator. Tighten Tighten the bolts to 28 N.m (21 lb ft).
3. Install the radiator.
4. Install the cooling fan and shroud. Refer to «COOLING FAN AND SHROUD REPLACEMENT»(ref-188500-S18182407622005090300000) .
5. Raise the vehicle.
6. Install the outlet radiator hose (1) to the radiator.
7. Reposition the outlet radiator hose clamp (1) using J 38185 .
8. Connect the transmission cooler lines to the radiator. Refer to «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000) .
9. Install the lower radiator support shield, if equipped.
10. Lower the vehicle.
11. Install the coolant recovery hose to the radiator.
12. Install the radiator support diagonal brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
13. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Scheme 117

Scheme 118

Scheme 119

1. Drain the engine coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Remove the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
3. Remove the harnesses from the engine harness bracket.
4. Remove the bolt that secures the engine harness bracket and remove the bracket.
5. Remove the coolant heater cord from the heater (2).
6. Remove the coolant heater from the block.

Scheme 120

Scheme 121

Scheme 122

1. Install the coolant heater to the engine block. Tighten Tighten the coolant heater to 50 N.m (37 lb ft).
2. Install the coolant heater cord to the heater (2). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
3. Install the engine harness bracket and secure the bracket with the bolt. Tighten Tighten the engine harness bracket bolt to 45 N.m (33 lb ft).
4. Secure the harnesses to the bracket.
5. Install the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
6. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Scheme 123

Scheme 124

1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .
2. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
3. Disconnect the coolant heater (1) electrical connector. IMPORTANT: Do not score the surface of the engine block hole when removing the coolant heater.
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

Scheme 125

Scheme 126

1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
2. Install the coolant heater to the engine block. Tighten Tighten the coolant heater to 50 N.m (37 lb ft). NOTE: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.
3. Connect the coolant heater (1) electrical connector.
4. Lower the vehicle.
5. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6)»(ref-188500-S35519897632005090300000) or «DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3)»(ref-188500-S24017915582005090300000) .

Scheme 127

Scheme 128

Scheme 129

1. If equipped with a 4.2L engine, remove the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
2. Remove the coolant heater cord from the engine harness bracket (1).
3. Remove the coolant heater cord from the coolant heater (2).
4. If equipped with a 5.3L engine, disconnect the coolant heater cord from the coolant heater (1).
5. Remove the coolant heater cord clip from the engine harness.
6. Disconnect the coolant heater cord retainers (1) from the battery cover.

Scheme 130

Scheme 131

Scheme 132

1. Connect the coolant heater cord retainers (1) to the battery cover.
2. If equipped with a 5.3L engine, connect the coolant heater cord to the coolant heater (1).
3. Install the coolant heater cord clip to the engine harness.
4. If equipped with a 4.2L engine, install the coolant heater cord to the coolant heater (2).
5. Install the coolant heater cord to the engine harness bracket (1).
6. Install the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .