SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 620 (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 is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. 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.
  3. Reposition the inlet hose clamp at the water crossover.
  4. Remove the inlet hose from the water crossover.
    Fig 1: Remove Inlet Hose
    G02109168Courtesy of GENERAL MOTORS CORP.
  5. Reposition the heater inlet hose clamp at the water crossover.
  6. Remove the heater inlet hose from the water crossover.
    Fig 2: Remove Heater Inlet Hose
    G02109169Courtesy of GENERAL MOTORS CORP.
  7. Reposition the bypass hose clamps at the water crossover and water pump.
  8. Remove the bypass hose.
    Fig 3: Remove Bypass Hose
    G02109170Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator. Refer to GENERATOR (4.3L ENGINE) or  GENERATOR (4.8L, 5.3L & 6.0L ENGINES)  or  GENERATOR (6.6L ENGINE)  or  GENERATOR (8.1L ENGINE)  .
  10. Remove the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (6.6 L DIESEL or  POWER STEERING PUMP REPLACEMENT (4.3 L)  or  POWER STEERING PUMP REPLACEMENT (4.8L, 5.3L AND 6.0L)  or  POWER STEERING PUMP REPLACEMENT (8.1L)  .
  11. Remove the generator bracket bolts and nut.
  12. Remove the generator bracket stud.
  13. Remove the generator bracket.
    Fig 4: Remove Generator Bracket, Bolts & Nut
    G02109171Courtesy 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: Remove Water Crossover, Gaskets & Bolts
    G02109172Courtesy 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: Remove Water Outlet, Bolts & Thermostat
    G02109173Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.