SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 115 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSENGINE COOLANT CROSSOVER PIPE REPLACEMENT (LZ4)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION 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.
    Fig 1: Identifying Radiator Surge Tank Inlet Hose Clamp
    GM1774996Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Remove the generator. Refer to Generator Replacement (L61) or Generator Replacement (LZ4) .
  3. Remove the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement .
  4. Remove the power steering pump. Refer to Power Steering Pump Replacement .
  5. Reposition the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
  6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way.
    7. Fig 2: Identifying Radiator Surge Tank Inlet Pipe Bolts
    GM1774997Courtesy of GENERAL MOTORS CORP.
  7. Remove the radiator surge tank pipe bolts (2).
  8. Remove the radiator surge tank pipe from the crossover pipe.
    9. Fig 3: Identifying Radiator Inlet Hose & Crossover Pipe
    GM1583647Courtesy of GENERAL MOTORS CORP.
  9. Reposition the radiator inlet hose clamp at the crossover pipe.
  10. Remove the radiator inlet hose from the crossover pipe.
    11. Fig 4: View Of Crossover Pipe And Thermal Bypass Hose
    GM1584078Courtesy of GENERAL MOTORS CORP.
  11. Reposition the thermal bypass hose clamp at the crossover pipe.
  12. Remove the thermal bypass hose from the crossover pipe.
    13. Fig 5: Identifying Coolant Crossover Pipe Bolts
    GM1584086Courtesy of GENERAL MOTORS CORP.
  13. Remove the coolant crossover pipe bolts (1-4).
  14. Remove the coolant crossover pipe.
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.