Radiator Replacement GMC Savana H2500

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

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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.

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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

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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.

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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.

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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) .

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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.

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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.