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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 336 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSTHERMOSTAT REPLACEMENT (8.1L)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Installation Procedure
WARNING: This page is about a different car, the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostat (3).
  2. Install the thermostat housing (1).
    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 thermostat housing bolts (2).

    Tighten 

    Tighten the thermostat housing bolts to 30 N.m (22 ft lbs).

    Fig 1: Installing Thermostat
    G01699546Courtesy of GENERAL MOTORS CORP.
  4. Install the inlet hose (1) to the thermostat housing.
  5. Tighten the inlet hose clamp.
    Fig 2: Installing Inlet Hose
    G01699547Courtesy of GENERAL MOTORS CORP.
  6. Install the air cleaner duct (3).
  7. Position and tighten the clamp (2) at the throttle body (1).

    Tighten 

    Tighten the air cleaner duct clamp to 4 N.m (35 in lbs).

    Fig 3: Installing Air Cleaner Duct
    G01699548Courtesy of GENERAL MOTORS CORP.
  8. Install the air cleaner.
  9. Install the air cleaner bolts.

    Tighten 

    Tighten the air cleaner bolts to 10 N.m (89 in lbs).

  10. Tighten the clamp at the air cleaner.

    Tighten 

    Tighten the air cleaner duct clamp to 4 N.m (35 in lbs).

    Fig 4: Installing Air Cleaner
    G01699549Courtesy of GENERAL MOTORS CORP.
  11. Connect the following electrical connectors:
    • MAF sensor (1)
    • IAT sensor (2)
  12. Add coolant until the correct level is reached.
    Fig 5: Connecting Electrical Connectors
    G01699550Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.