GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Express 🢒 Engine 🢒 Engine Cooling 🢒 Cooling Layer Installation

Special Tools

J 38185 Hose Clamp Pliers

  1. Position the core support and the cooling layer to the vehicle.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1728562 Size: SH
  2. Install the 4 LH and RH core support bolts.

    3. Tighten
    Tighten the core support bolts to 25 N·m (18 lb ft).


    Object Number: 1665180 Size: SH
  3. Position the positive battery to underhood bused electrical center (UBEC) cable to the junction block and install the nut.

    4. Tighten
    Tighten the positive battery cable to junction block bolt to 8 N·m (71 lb in).


    Object Number: 1662151 Size: SH
  4. Position the auxiliary positive cable to the junction block and install the nut.

    5. Tighten
    Tighten the auxiliary positive battery cable to junction block bolt to 8 N·m (71 lb in).


    Object Number: 1662147 Size: SH
  5. Position the positive battery cable to the junction block and install the nut.

    6. Tighten
    Tighten the positive battery cable to junction block bolt to 8 N·m (71 lb in).

  6. Reposition and connect the hood release cable to the hood release latch.
  7. Connect the wiring harness electrical connector at the UBEC.

    8. Object Number: 1730624 Size: SH
  8. Position the LH fender to core support brace and install the bolts.

    9. Object Number: 1730623 Size: SH
  9. Position the wiring ground to the LH fender and install the bolt.

    10. Tighten
    Tighten the ground bolt to 9 N·m (80 lb in).


    Object Number: 1730625 Size: SH
  10. Position the RH fender to core support brace and install the bolts.
  11. Clip the wiring harness to the tie bar.

    12. Object Number: 1652913 Size: SH
  12. Connect the suction hose (4) to the air conditioning (A/C) compressor.
  13. Install the suction hose bolt (1) to the A/C compressor.

    14. Tighten
    Tighten the suction hose bolt to 16 N·m (12 lb ft).

  14. Position the evaporator to condenser hose to the condenser.

    15. Object Number: 924814 Size: SH
  15. Install the evaporator to condenser hose nut.

    16. Tighten
    Tighten the evaporator to condenser nut to 16 N·m (12 lb ft).


    Object Number: 1731100 Size: SH
  16. Position the transmission cooler line to the auxiliary transmission cooler and install the retaining clip.

    17. Object Number: 1731106 Size: SH
  17. Position the upper transmission cooler line to the radiator and install the retaining clip.
  18. Lower the vehicle.

    19. Object Number: 1652251 Size: SH
  19. Position the radiator outlet hose to radiator and install the retaining clip.
  20. Connect the radiator inlet hose to the radiator.

    21. Object Number: 1728635 Size: SH
  21. Using the J 38185 , reposition the radiator inlet hose clamp.
  22. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
  23. Install the front bumper. Refer to Front Bumper Replacement .
  24. Install the front grille. Refer to Grille Replacement .
  25. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
  26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacementfor 4.3L engine and Air Cleaner Assembly Replacementfor 4.8L, 5.3L, 6.0L engines.
  27. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  28. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging .
  29. Fill the cooling system. Refer to Cooling System Draining and Filling .