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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 881 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR SURGE TANK REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2001 GMC Yukon XL, 2001 GMC Yukon, 2001 GMC Sierra, 2001 GMC Cab & Chassis Sierra, and 2001 GMC C3500 HD. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Surge Tank, Nuts & Bolts
    GM362165Courtesy of GENERAL MOTORS COMPANY
  1. Install the surge tank.

    Refer to FASTENER NOTICE in Cautions and Notices.

  2. Install the surge tank bolt and nut.

    Tighten 

    Tighten the surge tank bolt and nut to 9 N.m (80 lb in).

    3. Fig 2: Surge Tank Outlet Hose
    GM721973Courtesy of GENERAL MOTORS COMPANY
  3. If equipped with a 6.6 L engine, install the surge tank outlet hose to the surge tank.
    4. Fig 3: View Of Surge Tank & Inlet Hose
    GM721988Courtesy of GENERAL MOTORS COMPANY
  4. If equipped with a 6.6 L engine, install the surge tank inlet hose (1) to the surge tank.
    5. Fig 4: View Of Surge Tank Outlet Hose & Surge Tank
    GM659059Courtesy of GENERAL MOTORS COMPANY
  5. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, install the surge tank inlet (1) and outlet (2) hoses to the surge tank.
  6. Position the surge tank inlet and outlet hose clamps.
    7. Fig 5: View Of Auxiliary Battery Relay, MAF, IAT & Coolant Level Sensor Electrical Connectors
    GM674702Courtesy of GENERAL MOTORS COMPANY
  7. Connect the low coolant level switch electrical connector (3).
    8. Fig 6: View Of Surge Tank & Overflow Hose
    GM659051Courtesy of GENERAL MOTORS COMPANY
  8. Install the surge tank overflow hose.
  9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement , in Engine Control - 4.3 L, Air Cleaner Assembly Replacement , in Engine Controls - 4.8 L, 5.3 L, and 6.0 L or Air Cleaner Assembly Replacement in Engine Control - 8.1 L.
  10. Fill the cooling system. Refer to Cooling System Draining and Filling .
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.