Engine Cooling System: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Reposition the coolant overflow hose clamp at the coolant recovery reservoir.
2. Remove the hose (1) from the reservoir.
3. Remove the coolant recovery reservoir retainer (1).
4. Remove the coolant reservoir (2).

Installation Procedure

1. Install the coolant reservoir (2).
2. Install the coolant recovery reservoir retainer (1).
3. Install the hose (1) to the reservoir.
4. Position the coolant overflow hose clamp at the coolant recovery reservoir.
5. Fill the coolant recovery reservoir, if necessary. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
2. Remove the left side diagonal brace. Refer to «Brace Replacement - Sheet Metal Diagonal (Chevrolet)»(ref-241699-S32208228052006081100000) , «Brace Replacement - Sheet Metal Diagonal (Pontiac)»(ref-241699-S01288087302006081100000) or «Brace Replacement - Sheet Metal Diagonal (Buick)»(ref-241699-S30005671862006081100000) in Body Front End.
3. Using the J 38185 (SA9111E), release tension on the hose clamp at the radiator until the clamp locks. See «Special Tools»(ref-241700-S25298036542006081100000) .
4. Remove the radiator inlet hose from the radiator.
5. Using the J 38185 (SA9111E), release tension on the hose clamp at the thermostat housing until the clamp locks. See «Special Tools»(ref-241700-S25298036542006081100000) .
6. Remove the radiator inlet hose from the thermostat housing.

1. Install the radiator inlet hose to the thermostat housing.
2. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the thermostat housing.
3. Install the radiator inlet hose to the radiator.
4. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the radiator.
5. Install the left side diagonal brace. Refer to «Brace Replacement - Sheet Metal Diagonal (Chevrolet)»(ref-241699-S32208228052006081100000) , «Brace Replacement - Sheet Metal Diagonal (Pontiac)»(ref-241699-S01288087302006081100000) or «Brace Replacement - Sheet Metal Diagonal (Buick)»(ref-241699-S30005671862006081100000) in Body Front End.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .
2. Using the J 38185 (SA9111E), release tension on the hose clamp at the water pump until the clamp locks. See «Special Tools»(ref-241700-S25298036542006081100000) .
3. Remove the radiator outlet hose from the water pump.
4. Raise and support the vehicle on a suitable hoist. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
5. Using the J 38185 (SA9111E), release tension on the hose clamp at the radiator until the clamp locks. See «Special Tools»(ref-241700-S25298036542006081100000) .
6. Remove the radiator outlet hose from the radiator.

1. Install the radiator outlet hose to the radiator.
2. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the radiator.
3. Lower the vehicle.
4. Install the radiator outlet hose to the water pump.
5. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the water pump.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) or «Draining and Filling Cooling System (Vac-N-Fill)»(ref-241700-S29801871252006081100000) .

1. Remove the air cleaner and duct assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
2. Remove right side diagonal brace. Refer to «Brace Replacement - Sheet Metal Diagonal (Chevrolet)»(ref-241699-S32208228052006081100000) , «Brace Replacement - Sheet Metal Diagonal (Pontiac)»(ref-241699-S01288087302006081100000) or «Brace Replacement - Sheet Metal Diagonal (Buick)»(ref-241699-S30005671862006081100000) in Body Front End.
3. Remove radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) .
4. Disconnect the cooling fan harness electrical connector.
5. Loosen the engine mount strut nuts at the engine side.
6. Remove the engine mount strut bracket brace bolts from the upper radiator support and rotate the struts and brackets rearward.
7. Reposition the coolant overflow hose clamp at the coolant recovery reservoir.
8. Remove the hose (1) from the reservoir.
9. Remove the overflow hose from the retainers. Position the hose aside.
10. Remove the battery. See Engine Electrical.
11. Remove the radiator upper mount bolts.
12. Remove the radiator upper mounts.
13. Remove the cooling fan shroud bolts.
14. Disconnect the upper transmission oil cooler (TOC) line from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) in Automatic Transaxle - 4T65-E.
15. Disconnect the TOC lines from the fan shroud retainer clip.
16. Remove the cooling fan shroud and fans.

1. Install the cooling fan shroud and fans.
2. Connect the TOC lines to the fan shroud retainer clip.
3. Connect the upper TOC line to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) in Automatic Transaxle - 4T65-E.
4. Install the cooling fan shroud bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
5. Install the radiator upper mounts.
6. Install the radiator upper mount bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
7. Install the battery. See Engine Electrical.
8. Position the hose. Install the overflow hose to the retainers.
9. Install the hose (1) to the reservoir.
10. Position the coolant overflow hose clamp at the coolant recovery reservoir.
11. Position the engine mount struts brackets flush with the upper radiator support.
12. Install the engine mount strut bracket brace bolts to the upper radiator support. Tighten: Tighten bolts to 28 N.m (21 lb ft).
13. Tighten the engine strut mount nuts at the engine side. Tighten: Tighten the nuts to 48 N.m (35 lb ft).
14. Connect the cooling fan harness electrical connector.
15. Install the radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) .
16. Install right side diagonal brace. Refer to «Brace Replacement - Sheet Metal Diagonal (Chevrolet)»(ref-241699-S32208228052006081100000) or «Brace Replacement - Sheet Metal Diagonal (Pontiac)»(ref-241699-S01288087302006081100000) or «Brace Replacement - Sheet Metal Diagonal (Buick)»(ref-241699-S30005671862006081100000) in Body Front End.
17. Install the air cleaner and duct assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).

1. Remove the air cleaner intake duct.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
3. Using the J 38185 , release the tension on the hose clamp at the thermostat housing and reposition the clamp.
4. Remove the radiator inlet hose from the thermostat housing.
5. Remove the thermostat housing bolts.
6. Remove the thermostat housing.

Scheme 6

1. Position the thermostat housing.
2. Install the thermostat housing bolts. Tighten: Tighten the bolt to 2.5 N.m (18 lb in).
3. Install the radiator inlet hose to the thermostat housing.
4. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the thermostat housing.
5. Install the air cleaner intake duct.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
2. Using the J 38185 , release the tension on the hose clamp at the thermostat housing and reposition the clamp.
3. Remove the radiator outlet hose from the thermostat housing.
4. Remove the thermostat housing bolt/stud.
5. Remove the thermostat housing.

1. Position the thermostat housing.
2. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt to 2.5 N.m (18 lb in).
3. Install the radiator outlet hose to the thermostat housing.
4. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the thermostat housing.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .

Scheme 7

1. Remove the thermostat housing. Refer to «Thermostat Housing Replacement - LX9 (3.5L)»(ref-241700-S10998962072007022300000) .
2. Remove the thermostat.
3. Remove and discard thermostat O-ring seal.

1. Install a NEW thermostat O-ring seal.
2. Install the thermostat.
3. Install the thermostat housing. Refer to «Thermostat Housing Replacement - LX9 (3.5L)»(ref-241700-S10998962072007022300000) .

Scheme 8

1. Remove the thermostat housing. Refer to «Thermostat Housing Replacement - LZ9 (3.9L)»(ref-241700-S09275069972007022300000) .
2. Remove the thermostat.

1. Install the thermostat.
2. Install the thermostat housing. Refer to «Thermostat Housing Replacement - LZ9 (3.9L)»(ref-241700-S09275069972007022300000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
2. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD REPLACEMENT - UPPER - 3.9L»(ref-241744-S03023357302006081100000) .
3. Remove the generator. Refer to «GENERATOR REPLACEMENT (LZ9)»(ref-241706-S01681761022007022100000) .
4. Remove the drive belt idler pulleys. Refer to «DRIVE BELT IDLER PULLEY REPLACEMENT»(ref-241744-S26177103222006081100000) .
5. Remove the power steering pump. Refer to «POWER STEERING PUMP REPLACEMENT»(ref-241712-S09659272492006081100000) .
6. Reposition coolant recovery reservoir inlet hose clamp (1) at coolant crossover.
7. Remove coolant recovery reservoir inlet hose (2) from coolant crossover.
8. Using J 38185 , release the tension on the hose clamp at the coolant crossover.
9. Remove radiator inlet hose from crossover pipe.
10. Reposition thermal bypass hose clamp at crossover pipe.
11. Remove thermal bypass hose from crossover pipe.
12. Remove bolt holding heater pipe and wiring harness at coolant crossover pipe.
13. Remove bolt holding the heater pipe on left cylinder head.
14. Position heater pipe aside.
15. Remove the coolant crossover pipe bolts (1-4).
16. Remove coolant crossover pipe.

Scheme 9

1. Position the coolant crossover pipe to the cylinder heads. NOTE: refer to «FASTENER NOTICE»(ref-241680-S40752786592006081100000) in Cautions and Notices.
2. Install the coolant crossover pipe bolts (1-4). Tighten: Tighten the bolt to 50 N.m (37 lb in).
3. Reposition the heater pipe.
4. Install bolt holding heater pipe to left cylinder head.
5. Install bolt holding heater pipe and wiring harness to coolant crossover pipe.
6. Install thermal bypass hose to crossover pipe.
7. Position thermal bypass hose clamp at crossover pipe.
8. Install radiator inlet hose to crossover pipe.
9. Using a small flat-bladed screwdriver, release hose clamp retention lock at coolant crossover.
10. Install coolant recovery reservoir inlet hose (2) to coolant crossover.
11. Position coolant recovery reservoir inlet hose clamp (1) at coolant crossover.
12. Install power steering pump. Refer to «POWER STEERING PUMP REPLACEMENT»(ref-241712-S09659272492006081100000) .
13. Install drive belt idler pulleys. Refer to «DRIVE BELT IDLER PULLEY REPLACEMENT»(ref-241744-S26177103222006081100000) .
14. Install generator. Refer to «GENERATOR REPLACEMENT (LZ9)»(ref-241706-S01681761022007022100000) .
15. Install intake manifold cover. Refer to «INTAKE MANIFOLD REPLACEMENT - UPPER - 3.9L»(ref-241744-S03023357302006081100000) .
16. Fill cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .

1. Drain cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
2. Loosen the water pump pulley bolts.
3. Remove drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-241709-S17523451682006081100000) .
4. Remove the water pump pulley bolts and pulley.
5. Remove the water pump bolts, pump, and gasket.
6. Clean the water pump mating surfaces.

Note. refer to FASTENER NOTICE in Cautions and Notices.

1. Install water pump gasket and pump.
2. Install the water pump bolts. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Install water pump pulley and bolts until snug.
4. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-241709-S17523451682006081100000) .
5. Tighten the water pump pulley bolts. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
7. Inspect for leaks.

1. Drain cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
2. Loosen the water pump pulley bolts.
3. Remove drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-241744-S07589734552006081100000) .
4. Remove the water pump pulley bolts and pulley.
5. Remove water pump bolts, pump, and gasket.
6. Clean the water pump mating surfaces.

Note. refer to FASTENER NOTICE in Cautions and Notices.

1. Install the water pump bolts. Tighten: Tighten the bolt to 10 N.m (89 lb in).
2. Install the water pump pulley and bolts until snug.
3. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-241744-S07589734552006081100000) .
4. Tighten the water pump pulley bolts. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
6. Inspect for leaks.

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) in Heating, Ventilation and Air Conditioning.
2. Disconnect the lower transmission oil cooler (TOC) line from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) in Automatic Transaxle - 4T65-E.
3. Remove the cooling fans and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-241700-S20760086572006081100000) .
4. Remove radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) .
5. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet»(ref-241700-S12285089082006081100000) .
6. Remove the A/C discharge hose to condenser block nut (1).
7. Disconnect the A/C discharge hose (2) from the condenser block.
8. Remove and discard the sealing washer.
9. Cap or tape off the A/C discharge hose.
10. Remove the evaporator inlet tube to condenser bolt (4).
11. Disconnect the evaporator inlet tube (3) from the condenser block.
12. Cap or tape off the evaporator inlet tube.
13. Remove the bolt that secures the radiator to the condenser.
14. Remove the condenser tube clip screw.
15. Tilt the radiator and condenser inwards toward the engine and remove the radiator.

1. Install the radiator.
2. Install the condenser tube clip screw. Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the bolt that secures the radiator to the condenser. Tighten: Tighten the bolt to 2.5 N.m (22 lb in).
4. Remove the cap or tape from the evaporator inlet tube.
5. Install a NEW sealing washer.
6. Connect the evaporator inlet tube (3) to the condenser block.
7. Install the evaporator inlet tube to condenser bolt (4). Tighten: Tighten bolt to 16 N.m (12 lb ft).
8. Remove the cap or tape off the A/C discharge hose.
9. Install a NEW sealing washer.
10. Connect the A/C discharge hose (2) to the condenser block.
11. Install the A/C discharge hose to condenser block nut (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
12. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet»(ref-241700-S12285089082006081100000) .
13. Install radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet»(ref-241700-S17953640892006081100000) .
14. Install the cooling fans and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-241700-S20760086572006081100000) .
15. Connect the lower transmission oil cooler (TOC) line to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) in Automatic Transaxle - 4T65-E.
16. Recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-241728-S41085286572006081100000) in Heating, Ventilation and Air Conditioning.
17. Leak test the fittings of A/C components using the J 39400-A . See «Special Tools»(ref-241700-S25298036542006081100000) .
18. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) in Automatic Transaxle - 4T65-E.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the air deflector bolts.
3. Remove the air deflector.

1. Install the air deflector.
2. Install the air deflector bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Lower the vehicle.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .
2. Disconnect the coolant heater cord (1) from the heater.
3. Remove the coolant heater.

Scheme 10

1. Remove any burrs, sealer, paint or other foreign material from the threads/sealing surface of the engine block and from the old coolant heater if the heater is to be reused.
2. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. NOTE: Refer to «COMPONENT FASTENER TIGHTENING NOTICE»(ref-241680-S29261683672006081100000) in Cautions and Notices.
3. Install the coolant heater to the engine block. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Connect the coolant heater cord (1) to the heater.
5. Fill cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(ref-241700-S12524063102006081100000) .

1. Raise and suitably support the vehicle. Refer to «VEHICLE LIFTING CAUTION»(ref-241680-S30778482592006081100000) .
2. Disconnect the coolant heater cord (1) from the coolant heater.
3. Remove coolant heater cord clip (3) from transaxle bracket.
4. Cut the coolant heater cord tie strap (2) securing the cord to the engine harness.
5. Cut the coolant heater cord tie straps (1) securing the cord to the engine harness.
6. Lower the vehicle.
7. Cut the tie strap (1) securing the coolant heater cord to the diagonal brace.
8. Remove the coolant heater cord.

Scheme 11

1. Install the coolant heater cord.
2. Install a NEW tie strap (1) securing the coolant heater cord to the diagonal brace.
3. Raise the vehicle.
4. Install the coolant heater cord clip (3) to the transaxle bracket.
5. Install a NEW tie strap (2) securing the cord to the engine harness.
6. Connect the coolant heater cord (1) to the coolant heater.
7. Lower the vehicle.