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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 407 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSCOOLANT CROSSOVER PIPE REPLACEMENT (8.1L)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 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.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. If replacing the water crossover install the following:
    1. Thermostat (3)
    2. Water outlet (1)
    3. Water outlet bolts (2)

      Tighten:  Tighten the bolts to 30 N.m (22 lb ft).

    2. Fig 1: View Of Water Outlet, Bolts & Thermostat
    GM635643Courtesy of GENERAL MOTORS CORP.
  2. Install NEW water crossover gaskets.
  3. Install the water crossover.
  4. Install the water crossover bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    5. Fig 2: View Of Engine Coolant Crossover & Gasket
    GM470698Courtesy of GENERAL MOTORS CORP.
  5. Install the generator bracket.
  6. Install the generator bracket stud.

    Tighten:  Tighten the stud to 20 N.m (15 lb ft).

  7. Install the generator bracket bolts and nut.

    Tighten:  Tighten the bolts and nut to 50 N.m (37 lb ft).

    8. Fig 3: View Of Generator Bracket, Bolts, Nuts & Stud
    GM751458Courtesy of GENERAL MOTORS CORP.
  8. Install the power steering pump. Refer to Power Steering Pump Replacement (8.1L) in Power Steering System.
  9. Install the generator. Refer to Generator Replacement (8.1L Engine) in Engine Electrical.
  10. Install the bypass hose.
  11. Position the bypass hose clamps at the water crossover and water pump.
    12. Fig 4: View Of Bypass Hose & Clamps
    GM846662Courtesy of GENERAL MOTORS CORP.
  12. Install the heater inlet hose to the water crossover.
  13. Position the heater inlet hose clamp at the water crossover.
    14. Fig 5: View Of Heater Inlet Hose & Water Crossover
    GM750694Courtesy of GENERAL MOTORS CORP.
  14. Install the inlet hose to the water crossover.
    15. Fig 6: View Of Inlet Hose Clamp & Water Crossover
    GM751425Courtesy of GENERAL MOTORS CORP.
  15. Position the inlet hose clamp at the water crossover.
  16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory in Engine Mechanical - 8.1 L.
  17. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
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.