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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1807 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR REPLACEMENT (LY7 STANDARD COOLING)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
WARNING: This page is about a different car, the 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the radiator.
  2. Connect the upper retainer pins of the side air baffle to the radiator.
  3. Connect the radiator outlet hose to the radiator. Use J 38185  to position the radiator outlet hose clamp to secure the hose. See Special Tools .
    4. Fig 1: View Of Radiator Inlet Hose
    GM1334988Courtesy of GENERAL MOTORS CORP.
  4. Connect the radiator inlet hose to the radiator. Use J 38185  to position the radiator inlet hose clamp to secure the hose. See Special Tools .
    5. Fig 2: Identifying Surge Tank Inlet Hose
    GM1334989Courtesy of GENERAL MOTORS CORP.
  5. Connect the surge tank inlet hose to the radiator. Use J 38185  to position the hose clamp to secure the hose. See Special Tools .
  6. Install the radiator/condenser upper support.
  7. Install the radiator support brackets.
    8. CAUTION: Refer to Fastener Caution .
  8. Install the radiator support bracket bolts and tighten to 9 N.m (80 lb in).
  9. Raise and support the vehicle.
    10. Fig 3: View Of Radiator Support Brackets
    GM1334986Courtesy of GENERAL MOTORS CORP.
  10. Connect the lower retainer pins of the side air baffle to the radiator.
    11. Fig 4: View Of Transmission Oil Ccooler (TOC) Mounting Bolts
    GM1350217Courtesy of GENERAL MOTORS CORP.
  11. Install the transmission oil cooler mounting bolts and tighten to 5 N.m (44 lb in).
    12. Fig 5: Locating Upper Condenser Mounting Bolts
    GM1349583Courtesy of GENERAL MOTORS CORP.
  12. Install the upper condenser mounting bolts and tighten to 5.4 N.m (48 lb in).
    13. Fig 6: View Of Condenser Lower Bracket Bolts
    GM1349581Courtesy of GENERAL MOTORS CORP.
  13. Install the lower condenser mounting bolts and tighten to 5.4 N.m (48 lb in).
  14. Lower the vehicle.
  15. Install the electric cooling fan assembly. Refer to Engine Coolant Fan Replacement (LY7)  .
  16. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716)  or Cooling System Draining and Filling (Static Fill) .
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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.