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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 467 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR REPLACEMENT (LH2 WITH OUT V92)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 2009 Cadillac STS. 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 (GE 47716)  or Cooling System Draining and Filling (Static Fill) .
  2. Remove the electric cooling fan. Refer to Engine Coolant Fan Replacement (LH2 Heavy Duty Cooling)  or Engine Coolant Fan Replacement (LH2 Standard Cooling) .
    3. Fig 1: Identifying Upper Condenser Mounting Bolts
    GM2147029Courtesy of GENERAL MOTORS CORP.
  3. Remove the upper condenser mounting bolts (1).
    4. Fig 2: Identifying Lower Condenser Mounting Bolts
    GM2147030Courtesy of GENERAL MOTORS CORP.
  4. Remove the lower condenser mounting bolts (1).
    5. Fig 3: Identifying Lower Retaining Pins of the Side Air Baffle
    GM2147033Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the lower retaining pins of the side air baffle from the radiator.
    6. NOTE: Reposition the condenser to access the transmission oil cooler mounting bolts.
  6. Remove the transmission oil cooler (TOC) mounting bolts (1).
  7. Lower the vehicle.
    8. Fig 4: Identifying Hose Clamp Pliers and Radiator Outlet Hose
    GM2147001Courtesy of GENERAL MOTORS CORP.
  8. Use J 38185:  Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator outlet hose (2) from the radiator.
    9. Fig 5: Identifying Radiator Inlet Hose and Radiator
    GM2146926Courtesy of GENERAL MOTORS CORP.
  9. Use J 38185:  Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the radiator inlet hose (2) from the radiator.
    10. Fig 6: Identifying Hose Clamp Pliers and Surge Tank Inlet Hose
    GM2147049Courtesy of GENERAL MOTORS CORP.
  10. Use J 38185:  Hose Clamp Pliers to disengage the tension on the hose clamp (1). Remove the surge tank inlet hose (2) from the radiator.
    11. Fig 7: Identifying Radiator Support Bolts and Brackets
    GM2147044Courtesy of GENERAL MOTORS CORP.
  11. Remove the radiator support bracket bolts (1).
  12. Remove the radiator support brackets (2).
  13. Disconnect the upper air baffle retaining pins from the radiator.
  14. Remove the radiator.
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.