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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMREPAIR INSTRUCTIONSRADIATOR REPLACEMENT (DIESEL)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
    Fig 1: Identifying Radiator Mounting Bolts
    GM1726332Courtesy of GENERAL MOTORS CORP.
  1. Install the radiator insulators.
    2. NOTE: Refer to Fastener Notice .
  2. Install the radiator to the charge air cooler.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  3. Install the radiator and charge air cooler as an assembly.
  4. Install the radiator mounting bolts to the charged air cooler.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

    5. Fig 2: View Of Fan Shroud
    GM834218Courtesy of GENERAL MOTORS CORP.
  5. Install the fan shroud bolts (1) to the top of the radiator support.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  6. Install the fan shroud bolts (3) to the sides of the fan shroud.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  7. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .
  8. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmissions or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmissions.
    9. Fig 3: View Of Radiator Inlet Hose
    GM834215Courtesy of GENERAL MOTORS CORP.
  9. Install the radiator inlet hose (5) to the radiator.
  10. Install the hose clamp at the radiator inlet housing using the J 38185  . See Special Tools .
  11. Install the outlet heater hose (2).
  12. Install the outlet heater hose clamp using the J 39529  . See Special Tools .
  13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (LMM) .
  14. Install oil fill tube. Oil Filler Tube Replacement .
  15. Install the upper radiator baffle.
  16. Install the battery. Refer to Battery Replacement (Primary) or Battery Replacement (Secondary) .
  17. Install the charged air cooler hose/pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement (Inlet) or Charged Air Cooler Hoses/Pipes Replacement (Outlet) .
  18. Install the surge tank assembly. Refer to Radiator Surge Tank Replacement .
  19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
    20. Fig 4: Identifying Air Cleaner Assembly
    GM1726280Courtesy of GENERAL MOTORS CORP.
  20. Install the upper radiator baffle.
  21. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities .
  22. Inspect the engine oil level. Refer to Approximate Fluid Capacities .
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.