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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 226 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER OUTLET HOUSING REPLACEMENT (LC3)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Water Outlet Housing
    GM1649745Courtesy of GENERAL MOTORS CORP.
  1. Assemble the water outlet housing if necessary. Refer to Water Outlet Housing Assemble .
  2. Install NEW water outlet housing gaskets.
  3. Install the water outlet housing with bypass hose to the vehicle.
    4. NOTE: Refer to Fastener Notice .
  4. Install the water outlet housing bolts.

    Tighten:  Tighten the water outlet housing bolts to 25 N.m (18 lb ft).

  5. Install the bypass hose clamp in the proper position.
  6. Install the radiator hose to the water outlet housing. Refer to Radiator Inlet Hose Replacement (LLT)  or Radiator Inlet Hose Replacement (LY7)  or Radiator Inlet Hose Replacement (LH2) .
  7. Install the two coolant hoses to the water outlet housing. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (LLT)  or Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)  or Radiator Surge Tank Inlet Hose/Pipe Replacement (LH2) .
    8. Fig 2: Supercharger Assembly
    GM1614621Courtesy of GENERAL MOTORS CORP.
  8. Install the supercharger idler pulley. Refer to Belt Idler Pulley Replacement - Supercharger .
  9. Install the supercharger belt tensioner. Refer to Drive Belt Tensioner Replacement - Supercharger .
  10. Install the supercharger assembly. Refer to Supercharger Replacement .
  11. Fill the charge air cooling system with coolant. Refer to Charge Air Cooling System Draining and Filling (Vac N Fill)  or Charge Air Cooling System Draining and Filling (Static Fill) .
  12. Fill the engine cooling system with coolant. Refer to Cooling System Draining and Filling (Static Fill)  or Cooling System Draining and Filling (GE 47716) .
  13. Check the engine cooling system for leaks.
  14. Check the charge air cooling system for leaks.
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.