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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 407 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK REPLACEMENTINSTALLATION 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.
  1. Install the surge tank.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the bolt to the surge tank.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  3. Install the nut to the surge tank.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    4. Fig 1: View Of Surge Tank, Nuts & Bolts
    GM362165Courtesy of GENERAL MOTORS CORP.
  4. Install the surge tank outlet hose (2) to the surge tank.
  5. Position the surge tank outlet hose clamp to the surge tank.
    6. Fig 2: View Of Surge Tank Outlet Hose & Surge Tank
    GM659059Courtesy of GENERAL MOTORS CORP.
  6. Install the surge tank inlet hose (1) to the surge tank.
    7. Fig 3: View Of Surge Tank & Inlet Hose
    GM721988Courtesy of GENERAL MOTORS CORP.
  7. Position the surge tank inlet hose clamp to the surge tank.
  8. Connect the coolant level sensor electrical connector (3).
    9. Fig 4: View Of Auxiliary Battery Relay, MAF, IAT & Coolant Level Sensor Electrical Connectors
    GM674702Courtesy of GENERAL MOTORS CORP.
  9. Install the surge tank overflow hose.
    10. Fig 5: View Of Surge Tank & Overflow Hose
    GM659051Courtesy of GENERAL MOTORS CORP.
  10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Control - 4.3 L, Air Cleaner Assembly Replacement in Engine Controls - 4.8 L, 5.3 L, and 6.0 L or Air Cleaner Assembly Replacement in Engine Control - 8.1 L.
  11. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)  or 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.