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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 336 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSTHERMOSTAT REPLACEMENT (6.5L)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION 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.
CAUTION: When adding coolant, use DEX-COOL coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

Important:  Thermostats must be replaced in pairs.

  1. Install the thermostats.
  2. Install the thermostat housing to the intake manifold.
    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 bolts to the housing.

    Tighten 

    Tighten the bolts to 42 N.m (31 ft lbs).

    Fig 1: Installing Thermostats, Thermostat Housing & Bolts
    G01699539Courtesy of GENERAL MOTORS CORP.
  4. Connect the radiator hose to the thermostat housing.
  5. Install the surge tank. Refer to Surge Tank Replacement .
  6. Install the air cleaner and the duct. Refer to AIR CLEANER ASSEMBLY .

    Important:  in order to properly fill a system that has been completely drained, use the air bleed vents, located on the thermostat housing.

  7. Refill the cooling system. Refer to Draining and Filling Cooling System .
  8. Bleed the air from the cooling system.
  9. Inspect the thermostat housing and the gasket for coolant leaks.
    Fig 2: Installing Surge Tank & Air Cleaner
    G01699540Courtesy 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.