Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2002CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 8.1 GREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMREPAIR INSTRUCTIONSCOOLANT BYPASS HOSE REPLACEMENTREMOVAL PROCEDURE

2002 Chevrolet Chevy Express G3500, Van Passenger Extended, 8.1 G

Removal Procedure

2002 Chevrolet Chevy Express G3500, Van Passenger Extended, 8.1 GSECTION Removal Procedure

Remove the air cleaner assembly. Refer to the appropriate procedure:
- For 6.5L, refer to AIR CLEANER ASSEMBLY
Drain the engine cooling system. Refer to Draining and Filling Cooling System .
Remove the coolant recovery reservoir or surge tank. Refer to Coolant Recovery Reservoir Replacement or Surge Tank Replacement .
Remove the upper fan shroud. Refer to Fan Shroud Replacement .
For vehicles with the 4.3L and 5.0/5.7L engines, disconnect the by-pass hose from the water pump.

Fig 1: Disconnecting By-Pass Hose (4.3L & 5.0/5.7L)

Courtesy of GENERAL MOTORS CORP.

For vehicles with the 8.1L engine, disconnect the by-pass hose from the water pump.

Fig 2: Disconnecting By-Pass Hose (8.1L)
Courtesy of GENERAL MOTORS CORP.
For vehicles with the 6.5L diesel engine, disconnect the by-pass hose from the water pump.
Remove the by-pass hose from the vehicle.

Fig 3: Disconnecting By-Pass Hose (6.5L)
Courtesy of GENERAL MOTORS CORP.

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.