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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 407 (ENGINE COOLING SYSTEM)DIAGNOSTIC INFORMATION AND PROCEDURESENGINE OVERHEATING
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Engine Overheating

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Engine Overheating
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
Engine Overheating

Step Action Yes No
1 Inspect the coolant level.
Is the coolant level low?		 Go to Step 11  Go to Step 2 
2 Inspect the exhaust system for the following conditions:
  • Damaged exhaust pipe
  • Plugged catalytic converter

Did you find and correct the condition?		 Go to Step 22  Go to Step 3 
3 Inspect for a loose drive belt.
Is the drive belt loose?		 Go to Step 4  Go to Step 5 
4 Replace the drive belt. Refer to Drive Belt Replacement in Engine Mechanical -4.3L, Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) or Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2) in Engine Mechanical - 4.8L, 5.3L and 6.0L, Drive Belt Replacement in Engine Mechanical - 6.6L or Drive Belt Replacement - Accessory in Engine Mechanical - 8.1L.
Was the repair complete?		 Go to Step 22  -
5
  1. Inspect for obstructed radiator air flow.
  2. If equipped with a 6.6L diesel, also inspect for an obstructed charged air cooler or debris between the radiator and air cooler.
Is the radiator air flow obstructed?		 Go to Step 6  Go to Step 7 
6 Clean the radiator. Refer to Radiator Cleaning .
Was the repair complete?		 Go to Step 22  -
7 Inspect for an inoperative fan clutch. Refer to Fan Clutch Diagnosis .
Is the fan clutch operating correctly?		 Go to Step 9  Go to Step 8 
8 Replace the fan clutch. Refer to Fan Clutch Replacement .
Was the repair complete?		 Go to Step 22  -
9 Inspect the thermostat. Refer to Thermostat Diagnosis .
Is the thermostat stuck in the closed position?		 Go to Step 10  -
10 Replace the thermostat. Refer to Thermostat Replacement (4.3L Engine)  or Thermostat Replacement (6.6L (LB7) Engine)  or Thermostat Replacement (6.6L (LLY) Engine)  or Thermostat Replacement (8.1L Engine) .
Was the repair complete?		 Go to Step 22  -
11
  1. Fill the coolant to the specified level.
  2. Perform a pressure test on the cooling system.
  3. Inspect for external coolant leaks.
Are there any external leaks?		 Go to Step 21  Go to Step 12 
12 Perform a pressure test on the radiator cap.
Does the radiator cap hold pressure?		 Go to Step 14  Go to Step 13 
13 Replace the radiator cap.
Was the repair complete?		 Go to Step 22  -
14 Inspect for combustion chamber gases leaking in the cooling system.
Are bubbles present in the coolant?		 Go to Step 19  Go to Step 17 
15 Inspect for a inoperative water pump.
Is the water pump inoperative?		 Go to Step 16  Go to Step 17 
16 Replace the water pump. Refer to Water Pump Replacement (4.3L Engine)  or Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines)  or Water Pump Replacement (6.6L (LB7) Engine)  or Water Pump Replacement (6.6L (LLY))  or Water Pump Replacement (8.1L) .
Was the repair complete?		 Go to Step 22  -
17 Inspect for a blockage in the engine block coolant passages.
Are the engine block coolant passages blocked?		 Go to Step 18  -
18 Perform the cooling system flush. Refer to Flushing .
Was the repair complete?		 Go to Step 22  -
19 Check the engine oil.
Is the engine oil foamy and/or milky?		 Go to Step 20  -
20
  1. Remove the cylinder head. Refer to Cylinder Head Replacement - Left or Cylinder Head Replacement - Right in Engine Mechanical - 4.3L, Cylinder Head Replacement - Left or Cylinder Head Replacement - Right in Engine Mechanical - 4.8L, 5.3L and 6.0L, Cylinder Head Replacement - Left or Cylinder Head Replacement - Right in Engine Mechanical - 6.6L, or Cylinder Head Replacement - Left or Cylinder Head Replacement - Right in Engine Mechanical - 8.1L.
  2. If equipped with a 8.1L engine, inspect the head gasket for correct installation. Refer to Cylinder Head Replacement - Left or Cylinder Head Replacement - Right in Engine Mechanical - 8.1 L.
  3. Inspect the cylinder head and block for cracks.
Was a damaged/faulty component found?		 Go to Step 21  -
21 Replace and/or repair the component as necessary.
Was the repair complete?		 Go to Step 22  -
22
  1. Fill the cooling system to the proper level, if necessary.
  2. Operate the engine.
Does the engine overheat?		 - System OK
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.