Engine Cooling System: Removal & Installation GMC Savana H1500

Removal Procedure

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the overflow hose from the surge tank.
3. Using J 38185 , reposition the surge tank inlet hose clamp. See «Special Tools»(ref-302123-S18057185742008102100000) .
4. Remove the surge tank inlet hose from the surge tank.
5. Using J 38185 , reposition the surge tank outlet hose clamp. See «Special Tools»(ref-302123-S18057185742008102100000) .
6. Disconnect the surge tank outlet hose from the surge tank.
7. Remove the surge tank retaining bolt.
8. Tilt the surge tank assembly and disconnect the surge tank electrical connector.
9. Remove the surge tank from the vehicle.

Installation Procedure

1. Connect the surge tank electrical connector.
2. Install the surge tank to the vehicle.
3. Install the surge tank retaining bolt. Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Install the surge tank outlet hose to the surge tank.
5. Using J 38185 , reposition the surge tank outlet hose clamp. See «Special Tools»(ref-302123-S18057185742008102100000) .
6. Install the surge tank inlet hose to the surge tank.
7. Using J 38185 , reposition the surge tank inlet hose clamp. See «Special Tools»(ref-302123-S18057185742008102100000) .
8. Install the overflow hose to the surge tank.
9. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Partially drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Disconnect the hose from the coolant recovery reservoir.
3. Remove the coolant recovery reservoir retaining screws.
4. Remove the coolant recovery reservoir.

1. Install the coolant recovery reservoir.
2. Install the coolant recovery reservoir retaining screws. Tighten: Tighten the screws to 6 N.m (53 lb in).
3. Connect the hose to the coolant recovery reservoir.
4. Add coolant to reservoir. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Using J 38185 reposition the surge tank inlet hose clamps. See «Special Tools»(ref-302123-S18057185742008102100000) .
3. Remove the surge tank inlet hose from the surge tank.
4. Remove the surge tank inlet hose from the radiator.

1. Install the surge tank inlet hose to the radiator.
2. Install the surge tank inlet hose to the surge tank.
3. Using J 38185 reposition the surge tank inlet hose clamp. See «Special Tools»(ref-302123-S18057185742008102100000) .
4. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000)
3. Reposition the clamp from the radiator inlet using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
4. Reposition the clamp from the engine using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
5. Remove the radiator inlet hose from the radiator.
6. Remove the radiator inlet hose from the engine.
7. Remove the radiator inlet hose (5).

1. Install the radiator inlet hose (5).
2. Install the radiator inlet hose to the radiator.
3. Install the radiator inlet hose to the engine.
4. Position the hose clamp from the engine using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
5. Position the hose clamp from the radiator inlet engine the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000)
7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the clamp at the radiator outlet using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
3. Remove the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
4. Remove the radiator outlet hose clamp at the coolant recovery reservoir using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
5. Disconnect the radiator outlet hose from the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-302123-S04362163362008102100000)
6. Disconnect the radiator outlet hose from the engine.
7. Remove the radiator outlet hose (4) from the engine compartment.

1. Install the radiator outlet hose (4) into the engine compartment.
2. Connect the radiator outlet hose to the engine.
3. Connect the radiator outlet hose to the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-302123-S04362163362008102100000)
4. Install the radiator outlet hose to the coolant recovery reservoir.
5. Install the radiator outlet hose clamp to the coolant recovery reservoir using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
6. Install the radiator outlet hose clamp to the engine using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the clamp at the radiator outlet using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
3. Remove the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
4. Remove the radiator outlet hose clamp at the coolant recovery reservoir using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
5. Remove the radiator outlet hose from the coolant recovery reservoir.
6. Remove the radiator outlet hose from the radiator.
7. Remove the radiator outlet hose from the engine.
8. Remove the radiator outlet hose (4).

1. Install the radiator outlet hose (4).
2. Install the radiator outlet hose to the engine.
3. Install the radiator outlet hose to the radiator.
4. Install the radiator outlet hose to the coolant recovery reservoir.
5. Install the radiator outlet hose clamp to the coolant recovery reservoir using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
6. Install the radiator outlet hose clamp to the engine using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
7. Install the radiator outlet clamp to the radiator outlet using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed.
3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1).

1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector.
2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots.
4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection.

1. Drain the coolant from the reservoir. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
3. Remove the vent hose from the throttle body.
4. Remove the vent hose from the radiator.
5. Remove the vent hose (1) from the vehicle.

1. Install the vent hose (1) to the vehicle.
2. Connect the vent hose to the radiator.
3. Connect the vent hose to the throttle body.
4. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
5. Fill the reservoir with coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe.
2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings.
4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors.
5. Clean all of the components in a suitable solvent, and dry them with compressed air.
6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary.

1. Install a new retaining ring into each quick connector fitting.
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector.
3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots.
5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection.
6. Snap the plastic cap onto the quick connect fitting.
7. Ensure that the plastic cap is fully seated against the fitting.
8. Ensure that no gap is present between the cap and the fitting.
9. Inspect and fill the engine oil to the proper level.

The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable.

1. Disconnect the cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-302123-S34136060202008102100000) .
2. Open the oil cooler hose clip located on the lower fan shroud.
3. Remove the oil cooler hoses from the clip.
4. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings.
5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
6. Remove the oil cooler hose bracket bolt (1).
7. Remove the oil cooler hose adapter bolts (2).
8. Remove the oil cooler hose assembly and gasket.
9. Discard the gasket.
10. Inspect the fittings, connectors and cooler hoses for damage or distortion.

1. Install the oil cooler hose assembly and a new gasket.
2. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the bolts to 12 N.m (106 lb in).
3. Install the oil cooler hose bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Install the oil cooler hoses to the hose clip on the fan shroud.
5. Snap the oil cooler hose clip shut.
6. Connect the oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-302123-S34136060202008102100000) .
7. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting.

1. If a fan assembly fails, inspect the hub and the drive components. A fan assembly may fail due to an imbalance in the hub. This type of failure may not be the fault of the blades.
2. Remove the fan clutch assembly. Refer to «Fan Clutch Replacement»(ref-302123-S03900721962008102100000) .
3. Remove the fan to fan clutch retaining bolts.
4. Remove the fan from the fan clutch.

1. Install the fan to the fan clutch.
2. Install the fan to fan clutch retaining bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
3. Install the fan clutch assembly. Refer to «Fan Clutch Replacement»(ref-302123-S03900721962008102100000) .

Fan Clutch Replacement

Special Tools

1. J 41240-5A Fan Clutch Wrench
2. J 46406 Fan Clutch Remover and Installer

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(ref-302123-S04607020132008102100000) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(ref-302123-S35076628672008102100000) .
2. Install the J 41240-5A onto the fan clutch nut. Install the J 46406 in order to secure the pulley.
3. Remove the fan clutch assembly.
4. Inspect the following components for cracks, distortion, or other damage: The belt The hub The adapter The pulley
5. Remove the cooling fan from the fan clutch. Refer to «Fan Replacement»(ref-302123-S01116626042008102100000) .

1. Install the cooling fan to the fan clutch. Refer to «Fan Replacement»(ref-302123-S01116626042008102100000) .
2. Install the fan clutch assembly to the pulley.
3. Install the J 41240-5A onto the fan clutch nut. Install the J 46406 in order to secure the pulley. Tighten: Tighten the nut to 95 N.m (70 lb ft).
4. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(ref-302123-S04607020132008102100000) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(ref-302123-S35076628672008102100000) .

Scheme 2

1. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-302104-S24614953572008102100000) .
2. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(ref-302156-S20208744242008102100000) .
3. Remove the EGR cooler pipe bolt.
4. Reposition the EGR cooler pipe (4) out of the way.
5. Remove the EGR valve adapter pipe bracket bolts (1).
6. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
7. Remove the exhaust gas recirculation (EGR) valve. Refer to «Exhaust Gas Recirculation Valve Replacement»(ref-302156-S28066719862008102100000) .
8. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement (LMM)»(ref-302188-S23689780122008102100000) .
9. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(ref-302123-S40927122912008102100000) .
10. Remove the turbocharger outlet cooling hose/pipe bolt from the valve cover.
11. Remove the turbocharger outlet cooling hose/pipe bolt.
12. Compress the clamp and disconnect the turbocharger cooling hose/pipe from the thermostat bypass pipe.
13. Remove the turbocharger outlet cooler pipe to turbocharger nut.
14. Remove the left bank fuel return line bracket bolt (1) and the two glow plug module bracket bolts (2).
15. Remove the left bank fuel line bracket bolt.
16. Remove the turbocharger outlet cooling hose/pipe to turbocharger bolt and remove the inlet hose/pipe.

1. Position the turbocharger inlet cooling hose/pipe to the vehicle.
2. Using new brass seals, install the turbocharger inlet cooling hose/pipe bolt. Tighten: Tighten the turbocharger inlet cooling hose/pipe bolt to 25 N.m (18 lb ft).
3. Position the left bank fuel line and install the bracket bolt. Tighten: Tighten the fuel line bracket bolt to 25 N.m (18 lb ft).
4. Position the glow module bracket to the valve cover, install the two bolts (2) and the remaining left bank fuel line bracket bolt (1). Tighten: Tighten the glow plug module bracket bolts to 10 N.m (89 lb in). Tighten the fuel line bracket bolt to 25 N.m (18 lb ft).
5. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
6. Install the EGR valve adapter pipe bracket bolts (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
7. Position the EGR cooler pipe (4).
8. Install the EGR cooler pipe bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
9. Install the turbocharger outlet cooler pipe to the turbocharger nut. Tighten: Tighten the turbocharger outlet pipe nut to 9 N.m (80 lb in).
10. Compress the clamp and connect the turbocharger cooling hose/pipe to the thermostat bypass pipe.
11. Install the turbocharger outlet cooling hose/pipe to the valve cover. Tighten: Tighten the turbocharger outlet pipe bolt to 9 N.m (80 lb in).
12. Install the turbocharger outlet cooling hose/pipe bolt. Tighten: Tighten the turbocharger outlet cooling hose/pipe bolt to 9 N.m (80 lb in).
13. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(ref-302123-S40927122912008102100000) .
14. Install the center intake manifold. Refer to «Center Intake Manifold Replacement (LMM)»(ref-302188-S23689780122008102100000) .
15. Install the EGR cooler tube replacement. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(ref-302156-S20208744242008102100000) .
16. Install the EGR valve. Refer to «Exhaust Gas Recirculation Valve Replacement»(ref-302156-S28066719862008102100000) .
17. Install the engine cover. Refer to «Engine Cover Replacement»(ref-302104-S24614953572008102100000) .
18. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn»(ref-302156-S26001170062008102100000) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-302156-S36459226082008102100000) .
2. Remove the engine cover. Refer to «Engine Cover Replacement»(ref-302104-S24614953572008102100000) .
3. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
4. Compress the clamp (1) and disconnect the turbocharger inlet cooling hose/pipe (2) from the thermostat housing.
5. Remove the EGR cooler pipe bolt.
6. Reposition the EGR cooler pipe (4) out of the way.
7. Remove the EGR valve adapter pipe bracket bolts (1).
8. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
9. Remove the left bank fuel return line bracket bolt (1) and the 2 glow plug module bracket bolts (2).
10. Remove the left bank fuel line bracket bolt.
11. Remove the turbocharger inlet cooling hose/pipe bolt and remove the inlet hose/pipe.

1. Position the turbocharger inlet cooling hose/pipe to the vehicle.
2. Using new brass seals, install the turbocharger inlet cooling hose/pipe. Tighten: Tighten the turbocharger inlet cooling hose/pipe bolt to 25 N.m (18 lb ft).
3. Position the left bank fuel line and install the bracket bolt. Tighten: Tighten the fuel line bolt to 25 N.m (18 lb ft).
4. Position the glow module bracket to the valve cover, install the 2 bolts (2) and the remaining left bank fuel line bracket bolt (1). Tighten: Tighten the glow plug module bracket bolts to 10 N.m (89 lb in). Tighten the fuel line bracket bolt to 25 N.m (18 lb ft).
5. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
6. Install the EGR valve adapter pipe bracket bolts (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
7. Position the EGR cooler pipe (4).
8. Install the EGR cooler pipe bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
9. Position the turbocharger inlet cooling hose/pipe (2) to the thermostat housing and position the compression clamp (1) to secure.
10. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
11. Install the engine cover. Refer to «Engine Cover Replacement»(ref-302104-S24614953572008102100000) .
12. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-302156-S36459226082008102100000) .

Scheme 3

1. Remove the bolt from the coolant recovery reservoir and reposition.
2. Remove air cleaner assembly.
3. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LU3)»(ref-302123-S41600959652008102100000) or «Radiator Outlet Hose Replacement (LR4, LM7, LQ4)»(ref-302123-S09678121422008102100000) .
4. Remove the water pump inlet bolts.
5. Remove the water pump inlet and thermostat from the water pump.

1. Install the thermostat and water pump inlet to the water pump.
2. Install the water pump inlet bolts. Tighten: Tighten the water pump inlet bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LU3)»(ref-302123-S41600959652008102100000) or «Radiator Outlet Hose Replacement (LR4, LM7, LQ4)»(ref-302123-S09678121422008102100000) .
4. Install the air cleaner assembly.
5. Install the coolant recovery reservoir and bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).

1. Remove the air cleaner and the duct assembly. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-302154-S00856158022008102100000) .
2. Partially drain the coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
3. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
4. Disconnect the radiator hose from the thermostat housing.
5. Remove the bolts attaching the thermostat housing to the thermostat.
6. Remove the thermostat housing.
7. Remove the thermostat.
8. Clean the gasket mating surfaces.

Note. Refer to COOLANT ADDITION NOTICE .

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold.
3. Install the bolts to the housing. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the radiator hose to the thermostat housing.
5. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
6. Install the air cleaner and the duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-302154-S00856158022008102100000) .
7. Refill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
8. Bleed the air from the cooling system.
9. Inspect the thermostat housing and the gasket for coolant leaks.

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(ref-302123-S04607020132008102100000) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(ref-302123-S35076628672008102100000) .
2. Remove the intake manifold. Refer to «Intake Manifold Tube Replacement (LMM)»(ref-302188-S24267329412008102100000) .
3. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
4. Compress the clamp and disconnect the radiator inlet hose from the thermostat housing.
5. Remove the fuel line bracket bolt and position the fuel line aside.
6. Compress the clamp and disconnect the turbocharger cooling inlet pipe from the thermostat housing.
7. Remove the 4 bolts and the thermostat housing.
8. Remove the thermostat and seals.

1. Install the thermostats and seals to the thermostat housing. The rear thermostat (4) has 2 vent valves. Install the vent valves towards the rear of the engine.
2. Position the thermostat housing and install the 4 bolts. Tighten: Tighten the thermostat housing bolt to 21 N.m (15 lb ft).
3. Compress the clamp and connect the turbocharger cooling inlet pipe to the thermostat housing.
4. Position the fuel line to the thermostat housing and install the fuel line bracket bolt. Tighten: Tighten the fuel line bracket bolt to 21 N.m (15 lb ft).
5. Compress the clamp and connect the radiator inlet hose to the thermostat housing.
6. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement (LMM)»(ref-302188-S24267329412008102100000) .
7. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L)»(ref-302123-S04607020132008102100000) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(ref-302123-S35076628672008102100000) .
8. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Remove the radiator fan. Refer to «Fan Replacement»(ref-302123-S01116626042008102100000) .
2. Remove the drive belt tensioner and generator bracket. Refer to «Generator Bracket Replacement (4.3L)»(ref-302110-S35143813882008102100000) or «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L)»(ref-302110-S10993215442008102100000) or «Generator Bracket Replacement (6.6L)»(ref-302110-S09733328882008102100000) .
3. Remove the air conditioning (A/C) and power steering bracket. Refer to «Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement (LLY, LBZ)»(ref-302188-S00798258522008102100000) .
4. Remove the fuel line bolt and position the fuel line aside.
5. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.
6. Remove the oil fill tube bolts and the oil fill tube.
7. Disconnect the coolant temperature sensor electrical connector.
8. Remove the exhaust gas recirculation (EGR) coolant pipe. Refer to «Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY, LBZ)»(ref-302123-S17235817792008102100000) .
9. Remove the fuel pipe bracket bolt.
10. Disconnect the hose at the thermostat bypass pipe.
11. Disconnect the radiator inlet hose from the thermostat housing.
12. Remove the thermostat bypass bolts at the water pump.
13. Remove the 8 thermostat housing crossover bolts.
14. Remove the thermostat housing crossover.

1. Position the thermostat housing crossover.
2. Install the 8 thermostat housing crossover bolts. Tighten: Tighten the thermostat housing crossover bolts to 25 N.m (18 lb ft).
3. Install the thermostat bypass bolts to the water pump. Tighten: Tighten to 21 N.m (16 lb ft).
4. Install the radiator inlet hose to the thermostat housing.
5. Connect the hose to the thermostat bypass pipe.
6. Install the fuel pipe bracket bolt. Tighten: Tighten the fuel pipe bracket bolt to 25 N.m (18 lb ft).
7. Install the EGR coolant pipe. Refer to «Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY, LBZ)»(ref-302123-S17235817792008102100000) .
8. Connect the coolant temperature sensor electrical connector.
9. Install the oil fill tube bolts and the oil fill tube. Tighten: Tighten the oil fill tube bolts to 25 N.m (18 lb ft).
10. Compress the clamp and connect the turbocharger inlet cooling hose/pipe.
11. Position the fuel line and install the fuel line bolt.
12. Install the A/C and power steering bracket. Refer to «Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement (LLY, LBZ)»(ref-302188-S00798258522008102100000) .
13. Install the drive belt tensioner and generator bracket. Refer to «Generator Bracket Replacement (4.3L)»(ref-302110-S35143813882008102100000) or «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L)»(ref-302110-S10993215442008102100000) or «Generator Bracket Replacement (6.6L)»(ref-302110-S09733328882008102100000) .
14. Instal the radiator fan. Refer to «Fan Replacement»(ref-302123-S01116626042008102100000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the coolant air bleed pipe bolts (1).
3. Remove the coolant air bleed pipe (2) with gaskets (3).
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 (2) and gaskets (3) onto the cylinder heads.
4. Install the coolant air bleed pipe bolts (1). Tighten: Tighten the coolant air bleed pipe bolts to 12 N.m (106 lb in).
5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) .
2. Remove the generator. Refer to «Generator Replacement (4.3L)»(ref-302110-S01745014132008102100000) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-302110-S29353362512008102100000) or «Generator Replacement (6.6L)»(ref-302110-S33663978962008102100000) .
3. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
4. Reposition the coolant air bleed hose clamp at the throttle body.
5. Remove the coolant air bleed hose from the throttle body.
6. Position the coolant air bleed hose clamp at the pipe.
7. 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. Install the generator. Refer to «Generator Replacement (4.3L)»(ref-302110-S01745014132008102100000) or «Generator Replacement (4.8L, 5.3L, and 6.0L)»(ref-302110-S29353362512008102100000) or «Generator Replacement (6.6L)»(ref-302110-S33663978962008102100000) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) .
7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

Scheme 4

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) .
2. Remove the air cleaner outlet resonator duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-302154-S00856158022008102100000) .
3. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
4. Remove the cooling fan.
5. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-302150-S20996798102008102100000) .
6. Reposition the radiator outlet hose clamps at the surge tank and water pump.
7. Remove the radiator outlet hose from the surge tank.
8. Remove the radiator outlet hose from the water pump.
9. Reposition the water pump inlet hose clamps.
10. Remove the water pump inlet hose.
11. Using J 41240 to hold the water pump pulley, remove the water pump pulley bolts. See «Special Tools»(ref-302123-S18057185742008102100000) .
12. Remove the water pump bolts.
13. Remove the water pump.
14. Remove and discard the water pump gaskets.
15. Clean and inspect the water pump, if necessary. Refer to «Water Pump Cleaning and Inspection»(ref-302150-S38845324242008102100000) .

1. If reusing the fasteners, apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts.
2. Install NEW water pump gaskets and the water pump. NOTE: Refer to «Fastener Notice»(ref-302102-S15003564942008102100000) .
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 45 N.m (33 lb ft).
4. Using J 41240 to hold the water pump pulley, install the water pump pulley bolts. See «Special Tools»(ref-302123-S18057185742008102100000) . Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
5. Install the water pump inlet hose.
6. Position the water pump inlet hose clamps.
7. Install the radiator outlet hose to the water pump.
8. Install the radiator outlet hose to the surge tank.
9. Position the radiator outlet hose clamps at the surge tank and water pump.
10. Install the drive belt. Refer to «Drive Belt Replacement»(ref-302150-S20996798102008102100000) .
11. Install the cooling fan.
12. Install the air cleaner outlet resonator duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-302154-S00856158022008102100000) .
13. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) .
14. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
15. Inspect the cooling system for leaks.

1. Remove the thermostat bypass pipes. Refer to «Thermostat Bypass Pipes Replacement»(ref-302123-S35853178792008102100000) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-302188-S00162892872008102100000) .
3. Remove the water pump to water pump outlet pipe nuts (2).
4. Remove the water pump nuts/bolts. Note the location of the bolts. The bolts are different lengths.
5. Remove the water pump.
6. Remove and discard the water pump O-ring and the water pump outlet pipe gasket.

1. Lubricate the water pump O-ring with engine oil.
2. Install the water pump outlet pipe gasket and water pump O-ring.
3. Install the water pump.
4. Install the water pump nuts/bolts. Ensure the correct length bolt is used in the proper location. Tighten: Tighten the nuts/bolts to 21 N.m (15 lb ft).
5. Install the water pump to water pump outlet pipe nuts (2). Tighten: Tighten the nuts to 25 N.m (18 lb ft).
6. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-302188-S00162892872008102100000) .
7. Install the thermostat bypass pipes. Refer to «Thermostat Bypass Pipes Replacement»(ref-302123-S35853178792008102100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
2. Remove the oil filter adapter and oil cooler assembly. Refer to «Oil Filter Adapter and Oil Cooler Assembly Replacement»(ref-302188-S22463502262008102100000) .
3. Remove the water pump to water pump outlet pipe nuts (2).
4. Remove the water pump to water pump outlet pipe studs (1).
5. Remove the water pump outlet pipe.
6. Remove and discard the water pump outlet pipe O-ring and gasket.

1. Install a NEW water pump outlet pipe O-ring onto the pipe.
2. Lubricate the O-ring seal with engine coolant.
3. Position a NEW water pump outlet pipe gasket to the water pump.
4. Install the water pump outlet pipe.
5. Install the oil filter adapter and oil cooler assembly. Refer to «Oil Filter Adapter and Oil Cooler Assembly Replacement»(ref-302188-S22463502262008102100000) .
6. Install the water pump to water pump outlet pipe studs (1). Tighten: Tighten the studs to 20 N.m (15 lb ft).
7. Install the water pump to water pump outlet pipe nuts (2). Tighten: Tighten the nuts to 25 N.m (18 lb ft).
8. Lower the vehicle.

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) for the 4.3L engine or «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, and 7.0L engines.
3. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-302154-S00856158022008102100000) for the 4.3L engine or «Air Cleaner Resonator Outlet Duct Replacement»(ref-302155-S35068599922008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, and 7.0L engines.
4. For the 4.3L engine, remove the air conditioning (A/C) suction hose. Refer to «Suction Hose Replacement (4.8L, 5.3L, 6.0L)»(ref-302117-S26127979162008102100000) for the 4.3L engine.
5. For the 4.8L, 5.3L and 6.0L engine, remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LU3, LR4, LM7, LQ4)»(ref-302123-S35264104012008102100000) .
6. Remove the battery cable from the fan shroud clips and reposition.
7. Remove the mass air flow (MAF) sensor wire from the fan shroud clip and reposition.
8. Remove the transmission oil lever indicator.
9. Remove the fan shroud bolts (1, 3, 4).
10. Remove the fan shroud (2, 5).

1. Install the fan shroud (2, 5).
2. Install the fan shroud bolts (1, 3, 4). Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the transmission oil lever indicator.
4. Install the MAF sensor wire to the fan shroud clip.
5. Install the battery cable to the fan shroud clips.
6. For the 4.3L engine, install the A/C suction hose. Refer to «Suction Hose Replacement (4.8L, 5.3L, 6.0L)»(ref-302117-S26127979162008102100000) for the 4.3L engine.
7. For the 4.8L, 5.3L and 6.0L engine, install the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LU3, LR4, LM7, LQ4)»(ref-302123-S35264104012008102100000) .
8. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-302154-S00856158022008102100000) for the 4.3L engine or «Air Cleaner Resonator Outlet Duct Replacement»(ref-302155-S35068599922008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, and 7.0L engines.
9. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, and 7.0L engines or «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) for the 4.3L engine.
10. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .

1. Remove the surge tank. Refer to «Radiator Surge Tank Replacement»(ref-302123-S38725540782008102100000) .
2. Remove the charge air cooler inlet and outlet hoses. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(ref-302188-S31690083802008102100000) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(ref-302188-S42899144452008102100000) .
3. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302156-S30515258882008102100000) .
4. Disconnect the fan clutch electrical connector, if equipped.
5. Remove the intake air heater. Refer to «Intake Air Heater Replacement»(ref-302156-S27665772162008102100000) .
6. Disconnect the cross car harness at buss bar on right core support.
7. Position cross car harness out of way.
8. Remove the transmission oil indicator.
9. Remove the engine oil indicator.
10. Remove the engine oil fill cap.
11. Remove the 2 upper fan shroud to core support bolts.
12. Remove the fan clutch electrical wiring harness routing clip, if equipped.
13. Remove the 4 upper fan shroud to lower fan shroud bolts.
14. Remove the upper fan shroud, while positioning the upper radiator hose.

1. Position the upper fan shroud in the vehicle, while positioning the upper radiator hose.
2. Install the 4 upper fan shroud to lower fan shroud bolts. Tighten: Tighten the upper fan shroud to lower fan shroud bolts to 6 N.m (53 lb in).
3. Install the fan clutch electrical wiring harness routing clip, if equipped.
4. Install the 2 upper fan shroud to core support bolts. Tighten: Tighten the upper fan shroud to core support bolts to 6 N.m (53 lb in).
5. Install the engine oil fill cap.
6. Install the engine oil indicator.
7. Install the transmission oil indicator.
8. Position back cross car harness.
9. Connect the cross car harness on buss bar at right core support.
10. Install the intake air heater. Refer to «Intake Air Heater Replacement»(ref-302156-S27665772162008102100000) .
11. Connect the fan clutch electrical connector, if equipped.
12. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302156-S30515258882008102100000) .
13. Install the charge air cooler inlet and outlet hoses. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(ref-302188-S31690083802008102100000) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(ref-302188-S42899144452008102100000) .
14. Install the surge tank. Refer to «Radiator Surge Tank Replacement»(ref-302123-S38725540782008102100000) .

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) for the 4.3L engine.
3. Remove the fan shroud bolts (1,3,4).
4. Remove the fan shroud (2,5).

1. Install the fan shroud (2,5).
2. Install the fan shroud bolts (1,3,4). Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) for the 4.3L engine.
4. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302156-S30515258882008102100000) .
2. Remove the upper fan shroud to lower fan shroud retaining bolts.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
4. Remove the lower fan shroud retaining bolts.
5. Remove the lower fan shroud from the vehicle.

1. Install the lower fan shroud to the vehicle.
2. Install the lower fan shroud retaining bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Lower the vehicle.
4. Install the upper fan shroud to lower fan shroud retaining bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302156-S30515258882008102100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302156-S30515258882008102100000) .
2. Remove the upper radiator baffle.
3. Remove the surge tank. Refer to «Radiator Surge Tank Replacement»(ref-302123-S38725540782008102100000) .
4. Remove battery. Refer to «Battery Replacement (Primary)»(ref-302110-S30264438032008102100000) or «Battery Replacement (Secondary)»(ref-302110-S08733837192008102100000) .
5. Remove the charged air cooler inlet hose/pipe. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(ref-302188-S31690083802008102100000) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(ref-302188-S42899144452008102100000) .
6. Remove the clamp at the radiator inlet using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
7. Remove the radiator inlet hose (5) from the radiator.
8. Remove the outlet heater hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
9. Remove the outlet heater hose (2) from the radiator.
10. Remove the automatic transmission cooler lines. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302137-S09326348552008102100000) for the 4L60-E/4L65-E/4L70-E transmissions or «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302160-S29579149052008102100000) for the 4L80-E/4L85-E transmissions.
11. Remove the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-302123-S34136060202008102100000) .
12. Remove the engine oil fill tube. Refer to «Oil Filler Tube Replacement»(ref-302188-S15552554572008102100000) .
13. Remove intake manifold tube. Refer to «Intake Manifold Tube Replacement (LMM)»(ref-302188-S24267329412008102100000) .
14. Remove the upper radiator baffle. Remove the fan shroud bolts (1) from the top of the radiator support.
15. Remove the fan shroud bolts (3) from the sides of the fan shroud.
16. Remove the radiator mounting bolts from the charged air cooler.
17. Remove the charge air cooler bolts to core support.
18. Remove the radiator and charge air cooler as assembly.
19. Remove radiator bolts to charge air cooler.
20. Remove the radiator insulators.
21. Inspect the following components: The radiator The insulators The hoses and clamps The mounting hardware Replace the components as necessary.

1. Install the radiator insulators.
2. Install the radiator to the charge air cooler. Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the radiator and charge air cooler as an assembly.
4. Install the radiator mounting bolts to the charged air cooler. Tighten: Tighten the bolts to 6 N.m (53 lb in).
5. Install the fan shroud bolts (1) to the top of the radiator support. Tighten: Tighten the bolts to 6 N.m (53 lb in).
6. Install the fan shroud bolts (3) to the sides of the fan shroud. Tighten: Tighten the bolts to 6 N.m (53 lb in).
7. Install the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-302123-S34136060202008102100000) .
8. Install the automatic transmission oil cooler lines. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302137-S09326348552008102100000) for the 4L60-E/4L65-E/4L70-E transmissions or «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302160-S29579149052008102100000) for the 4L80-E/4L85-E transmissions.
9. Install the radiator inlet hose (5) to the radiator.
10. Install the hose clamp at the radiator inlet housing using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
11. Install the outlet heater hose (2).
12. Install the outlet heater hose clamp using the J 39529 . See «Special Tools»(ref-302123-S18057185742008102100000) .
13. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement (LMM)»(ref-302188-S24267329412008102100000) .
14. Install oil fill tube. «Oil Filler Tube Replacement»(ref-302188-S15552554572008102100000) .
15. Install the upper radiator baffle.
16. Install the battery. Refer to «Battery Replacement (Primary)»(ref-302110-S30264438032008102100000) or «Battery Replacement (Secondary)»(ref-302110-S08733837192008102100000) .
17. Install the charged air cooler hose/pipe. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(ref-302188-S31690083802008102100000) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(ref-302188-S42899144452008102100000) .
18. Install the surge tank assembly. Refer to «Radiator Surge Tank Replacement»(ref-302123-S38725540782008102100000) .
19. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302156-S30515258882008102100000) .
20. Install the upper radiator baffle.
21. Inspect the automatic transmission fluid level. Refer to «Approximate Fluid Capacities»(ref-302187-S41930729832008102100000) .
22. Inspect the engine oil level. Refer to «Approximate Fluid Capacities»(ref-302187-S41930729832008102100000) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) for the 4.3L engine.
2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
3. Remove the clamp at the radiator inlet using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
4. Remove the radiator inlet hose (5) from the radiator.
5. Remove the outlet heater hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
6. Remove the outlet heater hose (2) from the radiator.
7. Remove the automatic transmission cooler lines. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302137-S09326348552008102100000) for the 4L60-E/4L65-E/4L70-E transmission or «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302160-S29579149052008102100000) for the 4L80-E/4L85-E transmission.
8. Remove the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-302123-S34136060202008102100000) .
9. Remove the fan shroud bolts (1) from the top of the radiator support.
10. Remove the fan shroud bolts (3) from the sides of the fan shroud.
11. Remove the radiator (2).
12. Remove the radiator insulators (1, 3).
13. Inspect the following components: The radiator The insulators The hoses and clamps The mounting hardware Replace the components as necessary.

1. Install the radiator insulators (1, 3).
2. Install the radiator (2).
3. Install the fan shroud bolts (1) to the top of the radiator support. Tighten: Tighten the bolts to 6 N.m (53 lb in).
4. Install the fan shroud bolts (3) to the sides of the fan shroud. Tighten: Tighten the bolts to 6 N.m (53 lb in).
5. Install the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-302123-S34136060202008102100000) .
6. Install the automatic transmission oil cooler lines. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302137-S09326348552008102100000) for the 4L60-E/4L65-E/4L70-E transmission or «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(ref-302160-S29579149052008102100000) for the 4L80-E/4L85-E transmission.
7. Install the radiator inlet hose (5) to the radiator.
8. Install the hose clamp at the radiator inlet housing using the J 38185 . See «Special Tools»(ref-302123-S18057185742008102100000) .
9. Install the outlet heater hose (2).
10. Install the outlet heater hose clamp using the J 39529 . See «Special Tools»(ref-302123-S18057185742008102100000) .
11. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-302123-S38824152132008102100000) .
12. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-302155-S14967576822008102100000) for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or «Air Cleaner Assembly Replacement»(ref-302154-S03600399182008102100000) for the 4.3L engine.
13. Inspect the automatic transmission fluid level. Refer to «Approximate Fluid Capacities»(ref-302187-S41930729832008102100000) .
14. Inspect the engine oil level. Refer to «Approximate Fluid Capacities»(ref-302187-S41930729832008102100000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Disconnect the heater cord from the coolant heater (4).
3. Loosen the coolant heater bolt.
4. Remove the coolant heater from the engine block.
5. Do not score the machined surface of the hole.
6. Grasp the plug with pliers.
7. Pull the plug from the engine block.
8. Clean the core plug hole in order to remove the following substances: Burrs Compound Paint Rough spots

1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 9985164 (Canadian P/N 10953480), or the equivalent.
2. Tightly push the coolant heater (1) into the engine block.
3. Tighten the coolant heater bolt until both of the locking wings draw tightly against the inner wall of the engine block. Tighten: Tighten the bolt to 2 N.m (18 lb in).
4. Connect the heater cord to the coolant heater (4).
5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
6. Inspect the cooling system for leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
3. Disconnect the coolant heater electrical connector (2).
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 electrical connector (2).
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-302143-S27448131102008102100000) .
3. Disconnect the engine coolant heater cord.
4. Loosen the coolant heater bolt.
5. Remove the engine coolant heater from the engine block.
6. Do not score the machined surface of the hole.
7. Grasp the plug with pliers.
8. Pull the plug from the engine block.
9. Clean the core plug hole in order to remove the following substances: Burrs Compound Paint Rough spots

1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 1052196 (Canadian P/N 5264008), or the equivalent.
2. Align the coolant heater element to point towards the top of the engine.
3. Tightly push the coolant heater into the engine block.
4. Tighten the bolt on the engine coolant heater until both of the locking wings draw tightly against the inner wall of the engine block. Tighten: Tighten the bolt to 2 N.m (18 lb in).
5. Connect the heater cord to the coolant heater.
6. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-302143-S27448131102008102100000) .
7. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-302123-S21188972162008102100000) or «Cooling System Draining and Filling (Vac N Fill)»(ref-302123-S36766816792008102100000) .
8. Inspect for coolant leaks.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
2. Disconnect the coolant heater electrical connector (1).
3. Remove the coolant heater cord retainer (1).
4. Remove the coolant heater cord retainers (1).
5. Remove the coolant heater cord.

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

1. Install the coolant heater cord.
2. Install the coolant heater cord retainer (1).
3. Install the coolant heater cord retainers (1).
4. Connect the coolant heater electrical connector (1).
5. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
2. Disconnect the coolant heater electrical connector (1).
3. Remove the coolant heater cord retainers (1).
4. Remove the coolant heater cord.

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

1. Install the coolant heater cord.
2. Install the coolant heater cord retainers (1).
3. Connect the coolant heater electrical connector (1).
4. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-302124-S03826668542008102100000) .
2. Disconnect the coolant heater electrical connector (1).
3. Remove the coolant heater cord retainer (1).
4. Remove the coolant heater cord retainer (1).
5. Remove the coolant heater cord retainer (1).
6. Remove the coolant heater cord.

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

1. Install the coolant heater cord.
2. Install the coolant heater cord retainer (1).
3. Install the coolant heater cord retainer (1).
4. Install the coolant heater cord retainer (1).
5. Connect the coolant heater electrical connector (1).
6. Lower the vehicle.