Engine Cooling System: Removal & Installation GMC Savana H2500

Removal Procedure

1. Partially drain the coolant. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
2. Disconnect the hose from the coolant recovery reservoir.
3. Remove the coolant recovery reservoir retaining screws.
4. Remove the coolant recovery reservoir.

Installation Procedure

1. Install the coolant recovery reservoir. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems
2. Install the coolant recovery reservoir retaining screws. Tighten Tighten the screws to 6 N.m (53 in lbs).
3. Connect the hose to the coolant recovery reservoir.
4. Add coolant to reservoir. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .

Radiator Hose Replacement - Inlet

Tools Required

J 38185 Hose Pliers

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
2. Reposition the clamp at the radiator inlet using the J 38185 .
3. Reposition the clamp at the thermostat housing using the J 38185 .
4. Remove the radiator inlet hose from the radiator.
5. Remove the radiator inlet hose from the thermostat housing.
6. Remove the radiator inlet hose (5).

Scheme 14

1. Install the radiator inlet hose (5).
2. Install the radiator inlet hose to the radiator.
3. Install the radiator inlet hose to the thermostat housing.
4. Position the hose clamp at the thermostat housing using the J 38185 .
5. Position the hose clamp at the radiator inlet housing using the J 38185 .
6. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .

Radiator Hose Replacement - Outlet

Tools Required

J 38185 Hose Pliers

Scheme 15

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
2. Remove the clamp at the radiator outlet using the J 38185 .
3. Remove the radiator outlet hose clamp at the engine using the J 38185 .
4. Remove the radiator outlet hose clamp at the coolant recovery reservoir using the J 38185 .
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 .
6. Install the radiator outlet hose clamp to the engine using the J 38185 .
7. Install the radiator outlet clamp to the radiator outlet using the J 38185 .
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .

Scheme 16

Scheme 17

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.

Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones.

Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting.

Scheme 18

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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. Important: Do not manually depress the retaining clip when installing the plastic cap.
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.

Scheme 25

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Scheme 29

1. Disconnect the cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) .
2. If equipped with a 6.0L engine, perform the following: Open the oil cooler hose clip located on the lower fan shroud. Remove the oil cooler hoses from the clip. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. Raise and suitably support the vehicle.
3. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hoses from the clip. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. Raise and suitably support the vehicle.
4. If equipped, remove the engine shield bolts.
5. Remove the engine shield.
6. If equipped with the a 6.0L engine, perform the following: Remove the oil cooler hose bracket bolt (1). Remove the oil cooler hose adapter bolts (2). Remove the oil cooler hose assembly and gasket. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
7. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hose bracket bolt. Disconnect the quick connect fittings (1) at the engine. Remove the oil cooler hose assembly. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.

Important: A distinct snap should be heard when assembling tube ends of the hose assembly to quick connectors. To ensure tube is fully inserted into the connector, check by giving tube a forceful pull.

Scheme 30

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Scheme 33

1. If equipped with a 6.0L engine, perform the following: Install the oil cooler hose assembly and a new gasket. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Install the oil cooler hose adapter bolts (2). Tighten Tighten the bolts to 12 N.m (106 in lbs). Install the oil cooler hose bracket bolt (1). Tighten Tighten the bolt to 25 N.m (18 ft lbs).
2. If equipped, install the engine shield.
3. Install the engine shield bolts. Tighten Tighten the bolts to 20 N.m (15 ft lbs).
4. If equipped with a 6.0L engine, perform the following: Install the oil cooler hoses to the hose clip on the fan shroud. Snap the oil cooler hose clip shut. Important: Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap on to the cooler line prior to cooler line installation. Do not use the plastic cap in order to install the cooler line into the fitting. Connect the oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) .
5. If equipped with a 8.1L engine, perform the following: Install the oil cooler hoses to the clip. Install the oil cooler lines to the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) . Insert the cooler line end into the quick connect fitting until a click is either heard or felt. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting.

Scheme 34

Scheme 35

1. Open the hood.
2. Disconnect the oil cooler lines from the auxiliary oil cooler. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) .
3. Remove the auxiliary oil cooler from the vehicle.

Scheme 36

Scheme 37

1. Install the auxiliary oil cooler.
2. Connect the oil cooler lines to the vehicle. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) .
3. Lower the vehicle.

Fan Replacement

Tools Required

1. J 38425 Fan Hub Wrench
2. J 38426 Pulley Strap Wrench

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 upper fan shroud. Refer to «Fan Shroud Replacement»(ref-173517-S30658070362005031700000) .
3. Insert the J 38426 around the pulley in order to secure the pulley. Insert the J 38425 onto the fan clutch nut.
4. Remove the following components: The fan (1) The fan clutch (2)
5. Inspect the following components for cracks, distortion, or other damage: The belts The hub The adapter The pulley
6. Replace the components, as necessary.

Scheme 38

1. Install the following components: The fan (1) The fan clutch (2) Tighten Tighten the fan clutch nut to 145 N.m (107 ft lbs).
2. Install the upper fan shroud. Refer to «Fan Shroud Replacement»(ref-173517-S30658070362005031700000) .

Fan Clutch Replacement

Tools Required

1. J 38425 Fan Hub Wrench
2. J 41240 Fan Clutch Remover and Installer

1. Remove the fan shroud bolts (1) from the top of the radiator support.
2. Remove the fan shroud bolts (3) from the sides of the fan shroud.
3. Remove the upper fan shroud (2).
4. Install the J 38425 onto the fan clutch nut. Install the J 41240 in order to secure the pulley.
5. Remove the fan clutch assembly.
6. Inspect the following components for cracks, distortion, or other damage: The belt The hub The adapter The pulley
7. Remove the bolts from the fan clutch.
8. Separate the fan clutch from the fan blade.

1. Install the fan clutch to the fan blade. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the bolts to the fan clutch. Tighten Tighten the bolts to 25 N.m (18 ft lbs).
3. Install the fan clutch assembly to the pulley.
4. Install the J 38425 onto the fan clutch nut. Install the J 41240 in order to secure the pulley. Tighten Tighten the nut to 95 N.m (70 ft lbs).
5. Install the upper fan shroud (2).
6. Install the fan shroud bolts (1) to the top of the radiator support. Tighten Tighten the bolts to 6 N.m (53 in lbs).
7. Install the fan shroud bolts (3) to the sides of the fan shroud. Tighten Tighten the bolts to 6 N.m (53 in lbs).

Important: The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly.

Scheme 39

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 Hose Replacement - Outlet»(ref-173517-S04484415472005031700000) .
4. Remove the water pump inlet bolts.
5. Remove the water pump inlet and thermostat from the water pump.

Scheme 40

1. Install the thermostat and water pump inlet to the water pump. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the water pump inlet bolts. Tighten Tighten the water pump inlet bolts to 15 N.m (11 ft lbs).
3. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet»(ref-173517-S04484415472005031700000) .
4. Install the air cleaner assembly.
5. Install the coolant recovery reservoir and bolt. Tighten Tighten the bolt to 11 N.m (97 in lbs).

Scheme 41

Scheme 42

1. Remove the air cleaner and the duct assembly.
2. Partially drain the coolant. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
3. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
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.

Scheme 43

Scheme 44

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Install the bolts to the housing. Tighten Tighten the bolts to 25 N.m (18 ft lbs).
4. Connect the radiator hose to the thermostat housing.
5. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
6. Install the air cleaner and the duct.
7. Refill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
8. Bleed the air from the cooling system.
9. Inspect the thermostat housing and the gasket for coolant leaks.

Scheme 45

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Scheme 48

1. Remove the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-159064-S19269375862005031600000) .
2. Remove the coolant air bleed pipe studs (1).
3. Remove the coolant air bleed pipe (2) with gaskets (3).
4. Remove the coolant air bleed pipe cover bolts (1) and covers (2).
5. Remove the gaskets from the coolant air bleed pipe and covers.
6. Discard the gaskets.
7. Remove the coolant air bleed hose (1) from the pipe (2).

Scheme 49

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Scheme 52

1. Install the coolant air bleed hose (1) onto the pipe (2). Important: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe.
2. Install the gaskets onto the coolant air bleed pipe and covers.
3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Install the coolant air bleed pipe studs (1). Tighten Tighten the coolant air bleed pipe studs to 12 N.m (106 in lbs).
5. Install the coolant air bleed pipe covers (2) and bolts (1). Tighten Tighten the coolant air bleed pipe cover bolts to 12 N.m (106 in lbs).
6. Install the intake manifold. Refer to «INTAKE MANIFOLD REPLACEMENT»(ref-159064-S19269375862005031600000) .

Scheme 53

Scheme 54

1. Remove the air cleaner assembly.
2. Remove the generator. Refer to «GENERATOR»(ref-167659-S37493647042004101900000) .
3. Partially drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
4. Reposition the coolant air bleed hose clamp at the throttle body.
5. Remove the coolant air bleed hose from the throttle body.
6. Reposition the coolant air bleed hose clamp at the pipe.
7. Remove the coolant air bleed hose (1) from the pipe (2).

Scheme 55

Scheme 56

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»(ref-167659-S37493647042004101900000) .
6. Install the air cleaner assembly.
7. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .

Water Pump Replacement (4.3L Engine)

Tools Required

J 41240 Fan Clutch Remover and Installer

Scheme 57

Scheme 58

Scheme 59

Scheme 60

1. Remove the air cleaner assembly.
2. Remove the air cleaner outlet resonator duct.
3. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
4. Remove the cooling fan. Refer to «Fan Replacement»(ref-173517-S11392130972005031700000) .
5. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-158806-S01513565082005031600000) .
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.
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-158806-S35814692042005031600000) .

Scheme 61

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Scheme 64

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. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Install the water pump bolts. Tighten Tighten the water pump bolts to 45 N.m (33 ft lbs).
4. Using J 41240 to hold the water pump pulley, install the water pump pulley bolts. Tighten Tighten the water pump pulley bolts to 25 N.m (18 ft lbs). Important: After assembly, the hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose.
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-158806-S01513565082005031600000) .
11. Install the cooling fan. Refer to «Fan Clutch Replacement»(ref-173517-S02876766052005031700000) .
12. Install the air cleaner outlet resonator duct.
13. Install the air cleaner assembly.
14. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
15. Inspect the cooling system for leaks.

Scheme 65

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Scheme 68

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
2. Remove the air cleaner assembly.
3. Remove the fan blade. Refer to «Fan Replacement»(ref-173517-S11392130972005031700000) .
4. Reposition the inlet hose clamp at the water pump.
5. Remove the inlet hose from the water pump.
6. Reposition the outlet hose clamp at the water pump.
7. Remove the outlet hose from the water pump.
8. Reposition the heater inlet hose clamp at the water pump.
9. Remove the heater inlet hose from the water pump.
10. Remove the accessory drive belt tensioner bolts and tensioner from the engine.
11. Remove the water pump bolts.
12. Remove the water pump and gaskets.
13. Discard the water pump gaskets.

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

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Install the water pump and NEW gaskets. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the water pump bolts. Tighten Tighten the water pump bolts a first pass to 15 N.m (11 ft lbs). Tighten the water pump bolts a final pass to 30 N.m (22 ft lbs).
3. Install the heater inlet hose to the water pump.
4. Position the heater inlet hose clamp at the water pump.
5. Install the outlet hose to the water pump.
6. Position the outlet hose clamp at the water pump.
7. Install the inlet hose to the water pump.
8. Position the inlet hose clamp at the water pump.
9. Install the accessory drive belt tensioner and bolts to the engine. Tighten Tighten the bolts to 50 N.m (37 ft lbs).
10. Install the accessory drive belt. Refer to «DRIVE BELT REPLACEMENT - ACCESSORY»(ref-159064-S25979498232005031600000) .
11. Install the fan blade. Refer to «Fan Replacement»(ref-173517-S11392130972005031700000) .
12. Install the air cleaner assembly.
13. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .

Scheme 73

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
2. Remove the fan shroud bolts (1,3,4).
3. Remove the fan shroud (2,5).

Scheme 74

1. Install the fan shroud (2,5). CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the fan shroud bolts (1,3,4). Tighten Tighten the bolts to 6 N.m (53 in lbs).
3. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .

Scheme 75

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
2. Remove the fan shroud bolts (1,3,4).
3. Remove the fan shroud (2,5).

Scheme 76

1. Install the fan shroud (2,5). CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the fan shroud bolts (1,3,4). Tighten Tighten the bolts to 6 N.m (53 in lbs).
3. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .

Scheme 77

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
2. Remove the fan shroud bolts (1,3,4).
3. Remove the fan shroud (2,5).

Scheme 78

1. Install the fan shroud (2,5). CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the fan shroud bolts (1,3,4). Tighten Tighten the bolts to 6 N.m (53 in lbs).
3. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) . .

Radiator Replacement

Tools Required

J 38185 Hose Clamp Pliers

Important: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the New radiator to be loose.

Scheme 79

Scheme 80

Scheme 81

1. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
2. Remove the clamp at the radiator inlet using the J 38185 .
3. Remove the radiator inlet hose (5) from the radiator.
4. Remove the clamp at the radiator outlet using the J 38185 .
5. Remove the radiator outlet hose (4) from the radiator.
6. Remove the outlet heater hose clamp at the radiator using the J 38185 .
7. Remove the outlet heater hose (2) from the radiator.
8. Remove the automatic transmission cooler lines. Refer to «OIL COOLER LINES»(ref-154976-S35937301572003060300000) for 4L60-E or «OIL COOLER LINES»(ref-156344-S35858138342003071400000) for 4L80-E.
9. Remove the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) .
10. Remove the fan shroud bolts (1) from the top of the radiator support.
11. Remove the fan shroud bolts (3) from the sides of the fan shroud.
12. Remove the radiator (2).
13. Remove the radiator insulators (1,3).
14. Inspect the following components: The radiator The insulators The hoses and clamps The mounting hardware Replace the components as necessary.

Scheme 82

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Scheme 84

1. Install the radiator insulators (1,3).
2. Install the radiator (2). CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Install the fan shroud bolts (1) to the top of the radiator support. Tighten Tighten the bolts to 6 N.m (53 in lbs).
4. Install the fan shroud bolts (3) to the sides of the fan shroud. Tighten Tighten the bolts to 6 N.m (53 in lbs).
5. Install the engine oil cooler lines. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-173517-S41907931762005031700000) .
6. Install the automatic transmission oil cooler lines. Refer to «OIL COOLER LINES»(ref-154976-S35937301572003060300000) for 4L60-E or «OIL COOLER LINES»(ref-156344-S35858138342003071400000) for 4L80-E.
7. Install the radiator outlet hose (4) to the radiator.
8. Install the radiator outlet clamp to the radiator outlet using the J 38185 .
9. Install the radiator inlet hose (5) to the radiator.
10. Install the hose clamp at the radiator inlet housing using the J 38185 .
11. Install the outlet heater hose (2).
12. Install the outlet heater hose clamp using the J 39529 .
13. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-173517-S28378941922005031700000) .
14. Inspect the automatic transmission fluid level.
15. Inspect the engine oil level.

Scheme 85

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
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

Scheme 86

Scheme 87

Scheme 88

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. Important: Avoid element contact with the inside walls of the engine block.
2. Tightly push the coolant heater (1) into the engine block. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
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 in lbs). CAUTION: 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.
4. Connect the heater cord to the coolant heater (4).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
6. Inspect the cooling system for leaks.

Scheme 89

Scheme 90

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .
2. Raise and suitably support the vehicle.
3. Disconnect the coolant heater electrical connector (2). Important: Do not score the surface of the engine block hole when removing the coolant heater.
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

Scheme 91

Scheme 92

1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the coolant heater to the engine block. Tighten Tighten the coolant heater to 50 N.m (37 ft lbs). CAUTION: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(ref-173517-S30886144552005031700000) .

Scheme 93

Scheme 94

1. Raise and suitably support the vehicle.
2. Disconnect the coolant heater electrical connector (2).
3. Remove the coolant heater cord retainer and bolts.
4. Remove the coolant heater cord.

Scheme 95

Scheme 96

1. Install the coolant heater cord. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
2. Install the coolant heater cord bolts and retainer. Tighten Tighten the coolant heater cord bolts to 8 N.m (71 in lbs).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.