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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 536 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR REPLACEMENT (LY7)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 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Radiator And Condenser Assembly
    GM825405Courtesy of GENERAL MOTORS CORP.
  1. Install the condenser to the radiator.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the mounting bolts that secure the condenser to the radiator.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  3. Install the condenser tube clip bolt.

    Tighten:  Tighten the bolt to 2.5 N.m (22 lb in).

  4. Install the radiator and condenser assembly.
  5. Remove the cap or the tape from the evaporator inlet tube.
  6. Install a new seal washer to the evaporator inlet tube. Refer to Sealing Washer Replacement .
    7. Fig 2: Identifying Evaporator Inlet Tube To Condenser Block
    GM825404Courtesy of GENERAL MOTORS CORP.
  7. Install the evaporator inlet tube and the bolt to the condenser block.

    Tighten:  Tighten bolt to 16 N.m (12 lb ft).

  8. Remove the cap or the tape from the A/C discharge hose.
  9. Install a new sealing washer to the A/C discharge hose. Refer to Sealing Washer Replacement .
    10. Fig 3: Locating A/C Discharge Hose From Condenser Block
    GM628885Courtesy of GENERAL MOTORS CORP.
  10. Install the A/C discharge hose and the nut to the condenser block.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

  11. Raise the vehicle.
  12. Connect the lower TOC line to the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting in Automatic Transaxle - 4T65-E.
    13. Fig 4: Locating Radiator Inlet/Outlet Hoses
    GM1462694Courtesy of GENERAL MOTORS CORP.
  13. Install the radiator outlet hose.
  14. Connect the radiator outlet hose to the radiator.
  15. Using J 38185  , reposition the hose clamp at the radiator to secure the hose. See Special Tools and Equipment .
  16. Lower the vehicle.
  17. Connect the radiator outlet hose to the engine
  18. Using J 38185  , reposition the hose clamp at the engine to secure the hose. See Special Tools and Equipment .
  19. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric (LA1)  or Cooling Fan Replacement - Electric (LY7) .
  20. Fill the cooling system. Refer to Draining and Filling Cooling System .
  21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  22. Using J 39400-A  , leak test the fittings of the component. See Special Tools and Equipment .
  23. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in Automatic Transaxle - 4T65-E.
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.