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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 316 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER CROSSOVER REPLACEMENT (8.1L ENGINE)REMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Yukon, 2003 Chevrolet Tahoe, 2003 Chevrolet Suburban, and 2003 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
  2. Remove the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT -- ACCESSORY in Engine Mechanical - 8.1 L.
  3. Position the inlet hose clamp at the water crossover.
  4. Remove the inlet hose from the water crossover.
    Fig 1: Removing Inlet Hose From Water Crossover
    G02117760Courtesy of GENERAL MOTORS CORP.
  5. Position the heater inlet hose clamp at the water crossover.
  6. Remove the heater inlet hose from the water crossover.
    Fig 2: Removing Heater Inlet Hose From Water Crossover
    G02117761Courtesy of GENERAL MOTORS CORP.
  7. Position the bypass hose clamps at the water crossover and water pump.
  8. Remove the bypass hose.
    Fig 3: Removing Bypass Hose
    G02117762Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator. Refer to GENERATOR (4.8L, 5.3L & 6.0L ENGINES) or GENERATOR (8.1L ENGINE) in Engine Electrical.
  10. Remove the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (4.8L, 5.3L AND 6.0L) or POWER STEERING PUMP REPLACEMENT (8.1L) in Power Steering System.
  11. Remove the generator bracket bolts and nut.
  12. Remove the generator bracket stud.
  13. Remove the generator bracket.
    Fig 4: Removing Generator Bracket
    G02117763Courtesy of GENERAL MOTORS CORP.
  14. Remove the water crossover bolts.
  15. Remove the water crossover.
  16. Remove and discard the water crossover gaskets.
    Fig 5: Removing Water Crossover
    G02117764Courtesy of GENERAL MOTORS CORP.
  17. If replacing the water crossover remove the following:
    1. 17.1. Water outlet bolts (2)
    2. 17.2. Water outlet (1)
    3. 17.3. Thermostat (3)
    Fig 6: Removing Thermostat
    G02117765Courtesy 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.