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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 232 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER PUMP REPLACEMENT (4.3L ENGINE)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.
  1. If reusing the fasteners, apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts.
  2. Install NEW water pump gaskets and the water pump.
    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 water pump bolts.

    Tighten 

    Tighten the water pump bolts to 45 N.m (33 ft lbs).

    Fig 1: Installing Water Pump Gaskets, Water Pump & Bolts
    G02079174Courtesy of GENERAL MOTORS CORP.
  4. Using J 41240  to hold the water pump pulley, install the water pump pulley bolts.

    Tighten 

    Tighten the water pump pulley bolts to 25 N.m (18 ft lbs).

    Fig 2: Installing Water Pump Pulley Bolts Using J 41240
    G02079175Courtesy of GENERAL MOTORS CORP.

    Important:  After assembly, the hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose.

  5. Install the water pump inlet hose.
  6. Position the water pump inlet hose clamps.
    Fig 3: Installing Water Pump Inlet Hose
    G02079176Courtesy of GENERAL MOTORS CORP.
  7. Install the radiator outlet hose to the water pump.
  8. Install the radiator outlet hose to the surge tank.
  9. Position the radiator outlet hose clamps at the surge tank and water pump.
    Fig 4: Installing Radiator Outlet Hose
    G02079177Courtesy of GENERAL MOTORS CORP.
  10. Install the drive belt. Refer to DRIVE BELT REPLACEMENT .
  11. Install the cooling fan. Refer to Fan Clutch Replacement .
  12. Install the air cleaner outlet resonator duct.
  13. Install the air cleaner assembly.
  14. Fill the cooling system. Refer to Draining and Filling Cooling System .
  15. Inspect the cooling system for leaks.
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.