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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 232 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSTHERMOSTAT REPLACEMENT (4.3L)INSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. 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.
  1. Install the thermostat.
  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 25 N.m (18 ft lbs).

    Fig 1: Installing Thermostat, Thermostat Housing & Bolts
    G02079156Courtesy of GENERAL MOTORS CORP.
  4. Connect the radiator hose to the thermostat housing.
  5. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
  6. Install the air cleaner and the duct.
  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: Connecting Radiator Hose
    G02079157Courtesy 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.