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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1238 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR REPLACEMENT (LZ4, LZ9)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the coolant. Refer to Cooling System Draining and Filling (L61) .
  2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  3. Remove the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
    4. Fig 1: View Of Upper Tie Bar And Condenser
    GM1202407Courtesy of GENERAL MOTORS CORP.
  4. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
    5. Fig 2: View Of Upper Radiator Support Brackets
    GM1202411Courtesy of GENERAL MOTORS CORP.
  5. Remove the upper radiator support bracket bolts.
  6. Remove the upper radiator support brackets.
    7. Fig 3: View Of Surge Tank Outlet Hose At Radiator
    GM1215548Courtesy of GENERAL MOTORS CORP.
  7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185  . See Special Tools .
  8. Remove the surge tank outlet hose from the radiator.
    9. Fig 4: View Of Radiator Inlet Hose And Radiator
    GM1203452Courtesy of GENERAL MOTORS CORP.
  9. Reposition the radiator inlet hose clamp at the radiator using the J 38185  . See Special Tools .
  10. Remove the radiator inlet hose from the radiator.
  11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    12. Fig 5: View Of Lower Radiator Air Deflector And Retainers
    GM1203537Courtesy of GENERAL MOTORS CORP.
  12. Remove the lower radiator air deflector retainers.
  13. Remove the lower radiator air deflector.
    14. Fig 6: View Of Right Front Fender Liner & Retainers
    GM1203530Courtesy of GENERAL MOTORS CORP.
  14. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  15. Remove the right radiator air deflector retainers.
  16. Remove the right radiator air deflector.
    17. Fig 7: View Of Left Radiator Air Deflector Retainers
    GM1203535Courtesy of GENERAL MOTORS CORP.
  17. Remove the left radiator air deflector retainers.
  18. Remove the left radiator air deflector.
    19. Fig 8: Identifying Radiator Outlet Hose And Engine
    GM1203449Courtesy of GENERAL MOTORS CORP.
  19. Reposition the radiator outlet hose clamp at the radiator using the J 38185  . See Special Tools .
  20. Remove the radiator outlet hose from the radiator.
    21. Fig 9: View Of Both Transmission Oil Cooler Pipes From Transmission
    GM1203519Courtesy of GENERAL MOTORS CORP.
  21. Place a drain pan under the transmission oil cooler pipes.
  22. Remove the transmission oil cooler pipe attachment nut from the transmission.
  23. Remove the transmission oil cooler pipes from the transmission.
    24. Fig 10: View Of Lower Radiator Support Bracket Bolts
    GM1203468Courtesy of GENERAL MOTORS CORP.
  24. Remove the lower radiator support bracket bolts.
  25. Remove the lower radiator support brackets.
  26. Remove the radiator lower mounts.
    27. Fig 11: View Of Radiator Lower Mounts
    GM1203511Courtesy of GENERAL MOTORS CORP.
  27. Remove and discard the condenser mounting bolts from the radiator.
    28. Fig 12: View Of Pushing Upward On Radiator & Downward On Condenser
    GM1201922Courtesy of GENERAL MOTORS CORP.
  28. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
  29. Remove and discard the condenser mounting nuts from the radiator.
    30. Fig 13: View Of Radiator Air Side Seals
    GM1336545Courtesy of GENERAL MOTORS CORP.
  30. Remove the radiator air side seals.
    31. Fig 14: View Of Radiator, Cooling Fan Shroud And Transmission Oil Cooler Pipe Assembly
    GM1202423Courtesy of GENERAL MOTORS CORP.
  31. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
  32. Remove the transmission oil cooler pipes from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
    33. Fig 15: View Of Fan Shroud Tabs And Radiator Clips
    GM1202424Courtesy of GENERAL MOTORS CORP.
  33. Pry upward on the fan shroud tabs at the radiator clips.
  34. Remove the cooling fan and shroud assembly.
RENDER: 1.0x

NO RELATED

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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.