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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 881 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER OUTLET TUBE 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 Water Outlet & Bolts
    GM699329Courtesy of GENERAL MOTORS COMPANY
  1. Install a new O-ring seal on the water outlet tube.
  2. Lightly lubricate the O-ring seal with coolant.
  3. Install the water outlet tube.
  4. Refer to FASTENER NOTICE in Cautions and Notices.

    Install the bolt retaining the water outlet tube to the thermostat housing.

    Tighten 

    Tighten the water outlet tube to thermostat housing bolt to 21 N.m (15 lb ft).

  5. Install the 2 bolts retaining the water outlet tube to the valve rocker arm cover.

    Tighten 

    Tighten the water outlet tube to valve rocker arm cover bolts to 21 N.m (15 lb ft).

    6. Fig 2: View Of Turbocharger Bypass Valve & Washer
    GM687052Courtesy of GENERAL MOTORS COMPANY
  6. Install the turbocharger bypass valve and sealing washer to the water outlet tube.

    Tighten 

    Tighten the turbocharger bypass valve to 60 N.m (44 lb ft).

    7. Fig 3: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS COMPANY
  7. Connect the turbocharger coolant hose to the turbocharger bypass valve.
    8. Fig 4: View Of Wiring Harness Bracket At Thermostat Housing
    GM699749Courtesy of GENERAL MOTORS COMPANY
  8. Install the bolt and wiring harness bracket to the thermostat housing.

    Tighten 

    Tighten the wiring harness bracket bolt to 8 N.m (71 lb in).

    9. Fig 5: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS COMPANY
  9. Install the radiator inlet hose to the water outlet tube.
  10. Fill the engine coolant. Refer to Cooling System Draining and Filling .
    11. Fig 6: Upper Intake Manifold Sight Shield
    GM658266Courtesy of GENERAL MOTORS COMPANY
  11. Install the upper intake manifold sight shield.

    Tighten 

    Tighten the upper intake manifold shield bolt to 9 N.m (80 lb in).

RENDER: 1.0x

NO RELATED

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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.