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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2618 (HYBRID/EV COOLING SYSTEM)REPAIR INSTRUCTIONSGENERATOR CONTROL MODULE COOLING SYSTEM DRAINING AND FILLINGFILLING PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Filling Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Filling Procedure
WARNING: This page is about a different car, the 2012 GMC Yukon, 2012 Chevrolet Tahoe, and 2012 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION:

    The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

  1. Install the generator control module coolant pump hose. Refer to Generator Control Module Coolant Pump Hose Replacement (Pump to Radiator) , Generator Control Module Coolant Pump Hose Replacement (Pump to Pump) .
  2. Using the J 38185  hose clamp pliers, reposition the generator control module coolant pump hose clamp.
  3. Install the generator control module coolant inlet hose. Refer to Generator Control Module Coolant Inlet Hose Replacement .
  4. Using the J 38185  hose clamp pliers, reposition the generator control module coolant inlet hose clamp.
  5. Lower the vehicle.
    6. NOTE:

    Use pre-mixed Dexcool only. Pre-mix DEXCOOL contains the proper 50/50 mixture of DEXCOOL and de-ionized water necessary to prevent corrosion damage to the generator control module internal heat sink. Never use tap water in the hybrid cooling system.

  6. Slowly fill the cooling system with the pre-mixed DEXCOOL. Refer to Approximate Fluid Capacities .
  7. Turn the ignition ON.
  8. As the cooling pumps run, air will purge into the surge tank and the coolant level will drop. Top off the coolant as necessary until the coolant is maintained at the Cold Full line.
  9. Inspect the concentration of the generator control module coolant using the J 26568  coolant and battery tester.
  10. Install the coolant pressure cap.
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.