Engine Cooling System: Removal & Installation GMC Envoy II

Removal Procedure

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-200372-S01633221522005102000000) in Engine Controls - 4.2L or to «Air Cleaner Assembly Replacement»(ref-200373-S23128732102005102000000) in Engine Controls - 5.3L.
2. Remove the accumulator. Refer to «Accumulator Replacement»(ref-200405-S40893416132005102000000) in Heating, Ventilation and Air Conditioning.
3. Remove the coolant hoses from the coolant recovery reservoir and plug the hoses and the coolant recovery reservoir outlets with suitable plugs (2).
4. Remove the nut and bolt securing the coolant recovery reservoir.
5. Remove the coolant recovery reservoir.

Installation Procedure

1. Install the coolant recovery reservoir.
2. Install the coolant recovery reservoir bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
3. Install the coolant recovery reservoir nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
4. Install the coolant hose to the coolant recovery reservoir (2).
5. Install the accumulator. Refer to «Accumulator Replacement»(ref-200405-S40893416132005102000000) in Heating, Ventilation and Air Conditioning.
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-200372-S01633221522005102000000) in Engine Controls - 4.2L or to «Air Cleaner Assembly Replacement»(ref-200373-S23128732102005102000000) in Engine Controls - 5.3L.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the air intake resonator. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
3. Using J 38185 reposition the radiator inlet hose clamp (1) from the engine.
4. Remove the outlet hose from the engine.
5. Using J 38185 reposition the radiator inlet hose clamp (2) from the radiator.
6. Remove the radiator outlet hose from the radiator.

1. Install the inlet hose to the radiator.
2. Using J 38185 reposition the radiator inlet hose clamp to the radiator.
3. Install the inlet hose to the engine.
4. Using J 38185 reposition the radiator inlet hose clamp to the engine.
5. Install the air intake resonator. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the air intake resonator. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200372-S36504693382005102000000) in Engine Controls - 4.2L.
3. Using J 38185 reposition the radiator inlet hose clamp (1) from the engine.
4. Remove the radiator outlet hose from the engine.
5. Using J 38185 reposition the radiator inlet hose clamp (2) from the radiator.
6. Remove the radiator inlet hose from the radiator.

1. Install the radiator inlet hose to the radiator.
2. Using J 38185 reposition the radiator inlet hose clamp to the radiator.
3. Install the radiator inlet hose to the engine.
4. Using J 38185 reposition the radiator inlet hose clamp to the engine.
5. Install the air intake resonator. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200372-S36504693382005102000000) in Engine Controls - 4.2L.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Using J 38185 reposition the radiator outlet hose clamp (3).
3. Remove the radiator outlet hose (2) from the radiator.
4. Using J 38185 reposition the radiator outlet hose clamp.
5. Remove the radiator outlet hose from the engine (5).
6. Remove the radiator outlet hose.

1. Install the radiator outlet hose to the engine (5).
2. Using J 38185 reposition the radiator outlet hose clamp (3).
3. Install the radiator outlet hose (2) to the radiator (1).
4. Using J 38185 reposition the radiator outlet hose clamp (3).
5. Lower the vehicle.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Using J 38185 reposition the radiator outlet hose clamp.
3. Remove the radiator outlet hose from the radiator.
4. Using J 38185 reposition the radiator outlet hose clamp.
5. Remove the radiator outlet hose from the engine (1).
6. Remove the radiator outlet hose.

1. Install the radiator outlet hose to the engine (1).
2. Using J 38185 reposition the radiator outlet hose clamp.
3. Install the radiator outlet hose to the radiator.
4. Using J 38185 reposition the radiator outlet hose clamp.
5. Lower the vehicle.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the vent inlet hose from the radiator.
3. Remove the vent inlet hose from the surge tank.

1. Install the vent inlet hose to the surge tank.
2. Install the vent inlet hose to the radiator.
3. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
2. Remove the push-pin and release the fan clutch electrical connector from the fan shroud.
3. Remove the fan clutch from the fan shroud.
4. Remove the bolts retaining the fan blade to the fan clutch.
5. Separate the fan blade from the fan clutch.

1. Assemble the fan blade to the fan clutch.
2. Install the 4 bolts to the fan blade. Tighten: Tighten the bolts to 27 N.m (20 lb ft).
3. Install the fan clutch to the fan shroud.
4. Install the push-pin to the fan clutch electrical connector.
5. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-200372-S01633221522005102000000) in Engine Controls - 4.2L.
3. Remove the air resonator assembly. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-200372-S19209944462005102000000) in Engine Controls - 4.2L.
4. Remove the inlet radiator hose. Refer to «Radiator Hose Replacement - Inlet (LM4)»(ref-200409-S38972980032005102000000) or «Radiator Hose Replacement - Inlet (LL8)»(ref-200409-S01016099022005102000000) .
5. Remove the transmission oil cooler lines from the fan shroud.
6. Disconnect the fan clutch electrical connector.
7. Using J 46406 remove the fan clutch from the water pump. See «Special Tools»(ref-200409-S17093269022005102000000) .
8. Remove the mounting bolts from the upper fan shroud.
9. Lift and push the fan shroud inward to clear the filler neck on the radiator.
10. Remove the fan and the shroud.

1. Install the fan and the shroud.
2. Install the mounting bolts to the upper fan shroud. Tighten: Tighten the bolts to 28 N.m (21 lb ft).
3. Using J 46406 install the fan clutch to the water pump. See «Special Tools»(ref-200409-S17093269022005102000000) .
4. Connect the fan clutch electrical connector.
5. Install the inlet radiator hose. Refer to «Hood Latch Support Replacement»(ref-200376-S02255384832005102000000) .
6. Install the air resonator assembly. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-200372-S19209944462005102000000) in Engine Controls - 4.2L.
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-200372-S01633221522005102000000) in Engine Controls - 4.2L.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

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.

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

1. Remove the necessary coolant from the radiator. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical
3. Loosen the outlet hose clamp at the thermostat housing (1). Remove the outlet hose from the thermostat housing.
4. Remove the thermostat housing 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.

1. Install the thermostat housing to the engine block.
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 housing (1). Secure the hose with the clamp.
5. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical
6. Fill the cooling system with specified coolant and concentration. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
7. Inspect all sealing surfaces for leaks after starting the engine.

1. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (LM4)»(ref-200409-S03812913112005102000000) or «Radiator Hose Replacement - Outlet (LL8)»(ref-200409-S30864356882005102000000) .
2. Remove the water pump inlet bolts.
3. Remove the water pump inlet and thermostat from the water pump.

1. Install the thermostat and thermostat housing to the water pump.
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 (LM4)»(ref-200409-S03812913112005102000000) or «Radiator Hose Replacement - Outlet (LL8)»(ref-200409-S30864356882005102000000) .

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).

1. Install the coolant air bleed hose (1) onto the pipe (2).
2. Install the gaskets onto the coolant air bleed pipe and covers.
3. Install the coolant air bleed pipe (1) and gaskets onto the cylinder heads.
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).

1. Reposition the coolant air bleed hose clamp at the throttle body.
2. Remove the coolant air bleed hose from the throttle body.
3. Reposition the coolant air bleed hose clamp at the pipe.
4. Remove the coolant air bleed hose (1) from the pipe (2).

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

1. Disconnect the radiator inlet hose from the water outlet housing. Refer to «Radiator Hose Replacement - Outlet (LM4)»(ref-200409-S03812913112005102000000) or «Radiator Hose Replacement - Outlet (LL8)»(ref-200409-S30864356882005102000000) .
2. Remove the power steering pump bracket. Refer to «Power Steering Pump Bracket Replacement»(ref-200416-S06280552442005102000000) in Power Steering System.
3. Remove the water outlet housing bolts.
4. Remove the water outlet housing and seal. Discard the old seal.

1. Remove any burrs or foreign material from the sealing surface of the engine cylinder head and the water outlet housing.
2. Install a NEW seal and the water outlet housing.
3. Install the water outlet housing bolts. Tighten: Tighten the water outlet bolts to 10 N.m (89 lb in).
4. Connect the radiator inlet hose to the water outlet housing. Refer to «Radiator Hose Replacement - Outlet (LM4)»(ref-200409-S03812913112005102000000) or «Radiator Hose Replacement - Outlet (LL8)»(ref-200409-S30864356882005102000000) .
5. Install the power steering pump bracket. Refer to «Power Steering Pump Bracket Replacement»(ref-200416-S06280552442005102000000) in Power Steering System.

1. Drain the coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
3. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-200396-S20666880032005102000000) 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-200396-S21222666012005102000000) in Engine Mechanical - 4.2L Unit Repair.
10. Discard and replace the gasket.

1. Install a new water pump gasket.
2. Install the water pump and secure the water pump with the bolts. Tighten: On the initial pass, tighten the bolts to 4 N.m (35 lb in). On the final pass, 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»(ref-200396-S20666880032005102000000) in Engine Mechanical - 4.2L.
8. Install the fan and the shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
9. Fill the cooling system with the specified coolant and concentration. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
10. Inspect for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass Airflow (MAF)/intake Air Temperature (IAT) sensor
3. Remove the air cleaner outlet duct bolt and duct.
4. Remove the accessory drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Accessory»(ref-200397-S18653146752005102000000) in Engine Mechanical - 5.3L.
5. Remove the cooing fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
6. Using the J 38185 , reposition the inlet hose clamp at the water pump.
7. Remove the inlet hose from the water pump.
8. Using the 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 the J 38185 , reposition the throttle body hose clamp at the throttle body.
12. Remove the hose from the throttle body.
13. Using the 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. Remove the water pump bolts.
16. Remove the water pump and gaskets.
17. Discard the water pump gaskets.

1. Install the water pump and NEW gaskets.
2. Install the water pump bolts. Tighten: On the initial pass, tighten the bolts to 15 N.m (11 lb ft). On the final pass, tighten the bolts to 30 N.m (22 lb ft).
3. Install the auxiliary heater inlet and outlet hose/pipe nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
4. Install the hose to the throttle body.
5. Using J 38185 , position the throttle body hose clamp at the throttle body.
6. Install the inlet and outlet hoses/pipes to the water pump.
7. Using J 38185 , position the auxiliary heater inlet and outlet hose/pipe clamps at the water pump.
8. Install the outlet hose to the water pump.
9. Using J 38185 , position the outlet hose clamp at the water pump.
10. Install the inlet hose to the water pump.
11. Using J 38185 , position the inlet hose clamp at the water pump.
12. Install the cooing fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
13. Install the accessory drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Accessory»(ref-200397-S18653146752005102000000) in Engine Mechanical - 5.3L.
14. Install the air cleaner outlet duct and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
15. 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).
16. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Drain the coolant from the radiator. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) in Heating, Ventilation, and Air Conditioning.
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
4. Remove the lower radiator support shield, if equipped. Refer to «Radiator Support Shield Replacement»(ref-200388-S31852738982005102000000) in Frame and Underbody.
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 «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-200406-S35093075842005102000000) in Automatic Transmission - 4L60-E/4L65-E.
8. Lower the vehicle.
9. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
10. Remove the radiator support diagonal brace. Refer to «Brace Replacement - Radiator Support Diagonal»(ref-200376-S25454043242005102000000) 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.

1. Install the condenser to the radiator.
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-200409-S21303519892005102000000) .
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 «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-200406-S35093075842005102000000) in Automatic Transmission - 4L60-E/4L65-E.
9. Install the lower radiator support shield, if equipped. Refer to «Radiator Support Shield Replacement»(ref-200388-S31852738982005102000000) in Frame and Underbody.
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»(ref-200376-S25454043242005102000000) in Body Front End.
13. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

Radiator Replacement (LM4)

Tools Required

1. J 41240 Fan Clutch Remover and Installer
2. J 38185 Hose Clamp Pliers

1. Drain the coolant from the radiator. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the lower radiator support shield, if equipped. Refer to «Radiator Support Shield Replacement»(ref-200388-S31852738982005102000000) in Frame and Underbody.
3. Remove the transmission cooler lines from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-200406-S35093075842005102000000) in Automatic Transmission - 4L60-E/4L65-E.
4. Reposition the outlet radiator hose clamp using J 38185 .
5. Remove the outlet radiator hose (1) from the radiator.
6. Lower the vehicle.
7. Reposition the inlet radiator hose clamp (1) using J 38185 .
8. Remove the inlet radiator hose from the radiator.
9. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
10. Remove the grille. Refer to «Air Inlet Grille Panel Replacement (Envoy, TrailBlazer)»(ref-200376-S13716093692005102000000) or «Air Inlet Grille Panel Replacement (Rainier)»(ref-200376-S08234043382005102000000) in Body Front End.
11. Remove the upper radiator to condenser bolts.
12. Remove the coolant recovery line from the radiator.
13. Lift upward on the condenser to remove from the radiator retaining tab.
14. Remove the radiator.

1. Install the radiator.
2. Install the condenser to the radiator retaining tab.
3. Install the coolant recovery line to the radiator.
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 (Envoy, TrailBlazer)»(ref-200376-S13716093692005102000000) or «Air Inlet Grille Panel Replacement (Rainier)»(ref-200376-S08234043382005102000000) in Body Front End.
6. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) .
7. Install the inlet radiator hose to the radiator.
8. Reposition the inlet radiator hose clamp (1) using J 38185 .
9. Raise the vehicle.
10. Install the outlet radiator hose (1) to the radiator.
11. Reposition the outlet radiator hose clamp (1) using J 38185 .
12. Connect the transmission cooler lines to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-200406-S35093075842005102000000) in Automatic Transmission - 4L60-E/4L65-E.
13. Install the lower radiator support shield, if equipped. Refer to «Radiator Support Shield Replacement»(ref-200388-S31852738982005102000000) in Frame and Underbody.
14. Lower the vehicle.
15. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
3. Remove the PCM mounting studs (5) and position the PCM out of the way.
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
5. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) in Engine Controls - 4.2L.
6. Disconnect the integral clip (3) from the wire harness bracket.
7. Remove the engine wire harness bracket bolt.
8. Position the engine electrical wire harness bracket with wires attached out of the way.
9. Remove the coolant heater cord from the heater (2).
10. Remove the coolant heater from the block.

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.
3. Install the coolant heater to the engine block. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
4. Install the coolant heater cord to the heater (2).
5. Properly position the engine electrical harness bracket to the intake manifold.
6. Install the engine electrical harness bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Connect the integral clip (3) to the wire harness bracket.
8. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-200372-S38494846302005102000000) in Engine Controls - 4.2L.
9. Connect the ECT sensor electrical connector (1).
10. Install the PCM mounting studs (5) to the intake manifold. Tighten: Tighten the studs to 6 N.m (53 lb in).
11. Install the PCM (1) onto the studs (5).
12. Install the PCM retaining bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
13. Install the PCM retaining nuts (6). Tighten: Tighten the nuts to 8 N.m (71 lb in).
14. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
3. Disconnect the coolant heater (1) electrical connector.
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads.
2. Install the coolant heater to the engine block. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
3. Connect the coolant heater (1) electrical connector.
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) .

1. If equipped with a 4.2L engine, remove the PCM. Refer to «Powertrain Control Module (PCM) Replacement»(ref-200372-S14326151672005102000000) in Engine Controls - 4.2L.
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.

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 (PCM) Replacement»(ref-200372-S14326151672005102000000) in Engine Controls - 4.2L.