This document provides instructions for draining and filling the cooling system of a 2009 Chevrolet Express using either a static or vacuum fill method. The static fill method involves draining the system, filling it with coolant through the upper radiator hose, running the engine to circulate coolant, and checking coolant levels. The vacuum fill method uses a vacuum tool to draw coolant into the system and remove air, ensuring proper fill without air pockets. Both methods specify using a 50/50 mix of DEX-COOL antifreeze and water, and checking coolant concentration after filling.

1. 2009 Chevrolet Express - AWD | Express, Savana (VIN G/H) Service Manual | Engine | Engine Cooling | Specifications |
Document ID: 1731971
Fastener Tightening Specifications
Application
Specification
Metric English
Air Cleaner Outlet Duct Clamp Screw (4.8L, 5.3L, and 6.0L) 7 N·m 62 lb in
Air Cleaner Outlet Duct Wingnut (4.3L) 3 N·m 27 lb in
Bypass Pipe to Water Pump Bolt (6.6L) 21 N·m 16 lb ft
Charged Air Cooler Duct Clamp (6.6L) 8 N·m 71 lb in
Coolant Air Bleed Pipe Stud/Bolt (4.8L, 5.3L, and 6.0L ) 12 N·m 106 lb in
Coolant Heater (4.8L, 5.3L, 6.0L) 50 N·m 37 lb ft
Coolant Heater Bolt (4.3L ) 2 N·m 18 lb in
Coolant Heater Bolt (6.6L ) 2 N·m 18 lb in
Coolant Heater Cord Bolt 8 N·m 71 lb in
Coolant Outlet Pipe Clip Bolt (6.6L) 9 N·m 80 lb in
Coolant Recovery Reservoir Bolt 11 N·m 97 lb in
Drive Belt Tensioner Bolt 50 N·m 37 lb ft
Engine Block Coolant Drain Plug (4.3L ) 20 N·m 15 lb ft
Engine Coolant Heater Cord Bracket Bolt 12 N·m 106 lb in
Engine Coolant Heater Cord Clip Bolt 12 N·m 106 lb in
Engine Coolant Temperature Sensor 20 N·m 15 lb ft
Exhaust Gas Recirculation (EGR) Coolant Pipe Bole (6.6L) 21 N·m 16 lb ft
Fan and Clutch Retaining Nut to Water Pump Pulley (4.3L) 57 N·m 42 lb in
Fan and Water Pump Pulley Bolt (4.3L) 25 N·m 18 lb ft
Fan Clutch Bolt (4.8L, 5.3L and 6.0L) 23 N·m 17 lb ft
Fan Clutch Nut (4.8L, 5.3L and 6.0L) 56 N·m 41 lb ft
Fan Clutch Retaining Bolts (4.3L) 33 N·m 24 lb ft
Fan Pulley Bolt/Nut (6.6L) 46 N·m 34 lb ft
Fan Shroud Bolt 9 N·m 80 lb in
Fuel Line to Fuel Injection Control Module Bolt (6.6L) 35 N·m 26 lb ft
Heater Inlet Pipe to Fuel Filter Bolt (6.6L) 21 N·m 16 lb ft
Heater Inlet Pipe to Thermostat Bolt (6.6L) 21 N·m 16 lb ft
Heater Outlet Hose Bracket Bolt (6.6L) 21 N·m 16 lb ft
Oil Cooler Hose Adapter Bolt (4.8L, 5.3L and 6.0L) 12 N·m 106 lb in
Oil Cooler Hose Bracket Bolt (4.8L, 5.3L and 6.0L) 25 N·m 18 lb ft
Oil Cooler Line Clip to Bracket Nut (4.3L) 12 N·m 106 lb in
Oil Cooler Line Fittings to the Oil Filter Base (4.3L) 17 N·m 13 lb ft
Oil Cooler Line Fittings to the Oil Filter Base (4.3L Auxiliary Oil Cooler) 35 N·m 26 lb ft
Oil Cooler Line Fittings to the Radiator (4.3L) 24 N·m 18 lb ft
Oil Level Indicator Tube and Transmission Fluid Fill Tube Lower Support
© 2010 General Motors Corporation. All rights reserved.
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2. Bolt (4.3L) 4 N·m 44 lb in
Radiator Bolt 25 N·m 18 lb ft
Surge Tank Bolt/Nut 9 N·m 80 lb in
Thermostat Housing Bolt (4.3L) 25 N·m 18 lb ft
Thermostat Housing Bolt (4.8L, 5.3L, and 6.0L) 15 N·m 11 lb ft
Thermostat Housing Cover Bolt (6.6L) 21 N·m 16 lb ft
Thermostat Housing Crossover Bolt (6.0L) 21 N·m 16 lb ft
Transmission Control Module (TCM) Cover Bolt 9 N·m 80 lb in
Transmission Control Module (TCM) Electrical Connector Bolt 8 N·m 71 lb in
Turbocharger Coolant Bypass Valve (6.6L) 60 N·m 44 lb ft
Turbocharger Coolant Feed Pipe Bracket Bolt (6.6L) 21 N·m 16 lb ft
Turbocharger Coolant Feed Pipe Nut (6.6L) 9 N·m 80 lb in
Turbocharger Coolant Inlet Banjo Bolt (6.6L) 25 N·m 18 lb ft
Turbocharger Coolant Outlet Pipe Bolt/Nut (6.6L) 9 N·m 80 lb in
Water Outlet Stud (4.3L Engine) 25 N·m 18 lb ft
Water Outlet Tube Bolt (6.6L) 21 N·m 16 lb ft
Water Pump Bolt (4.3L ) 45 N·m 33 lb ft
Water Pump Bolt (6.6L ) 21 N·m 16 lb ft
Water Pump Bolt (4.8L, 5.3L, and 6.0L)
l First Pass 15 N·m 11 lb ft
l Final Pass 30 N·m 22 lb ft
Water Pump Inlet Pipe Bolt (6.6L) 21 N·m 16 lb ft
Wiring Harness Bracket to Thermostat Housing Bolt (6.6L) 8 N·m 71 lb in
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3. 2009 Chevrolet Express - AWD | Express, Savana (VIN G/H) Service Manual | Engine | Engine Cooling |
Repair Instructions | Document ID: 2123800
Cooling System Draining and Filling (Static Fill)
Special Tools
Draining Procedure
Warning: With a pressurized cooling system, the coolant temperature in the radiator can be
considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the
surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil
instantaneously with explosive force. This will cause the solution to spew out over the engine, the
fenders, and the person removing the cap. Serious bodily injury may result.
1. Park the vehicle on a level surface.
2. Remove the coolant pressure cap.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Place a drain pan under the lower radiator hose.
5. Using the J 38185 reposition the lower radiator hose clamp at the radiator.
6. Remove the lower radiator hose from the radiator.
7. Drain the cooling system.
8. If a complete engine block drain is required, remove the engine block drain plug.
9. Inspect the coolant.
10. Follow the appropriate procedure based on the condition of the coolant.
Filling Procedure
Caution: The procedure below must be followed. Improper coolant level could result in a low
or high coolant level condition, causing engine damage.
1. Connect the lower radiator hose.
2. Using the J 38185 position the clamp into the original position on the hose.
3. If the engine block drain plug was removed, perform the following:
4. Lower the vehicle.
5. Using the J 38185 , position the upper radiator hose clamp at the radiator.
6. Remove the upper radiator hose from the radiator.
7. Remove the coolant air bleed hose from the radiator.
• J 26568 Coolant and Battery Tester
• J 38185 Hose Clamp Pliers
• Normal in appearance--Follow the filling procedure.
• Discolored--Follow the flush procedure. Refer to Flushing.
3.1. Apply pipe sealer to the drain plug.
3.2. Install the drain plug and tighten to 22 N·m (16 lb ft).
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4. 8. Place a funnel into the upper radiator hose.
Note: Use a 50/50 mixture of DEX-COOL antifreeze and deionized water.
9. Slowly fill the cooling system through the upper radiator hose with a 50/50 coolant mixture
until the coolant comes out the coolant air bleed hose. Refer to Approximate Fluid Capacities.
10. Connect the upper radiator hose to the radiator.
11. Using the J 38185 position the radiator hose clamp into the original position on the hose.
12. Connect the coolant air bleed hose to the radiator.
13. Fill the radiator with coolant through the filler neck.
14. Install the coolant pressure cap.
15. Fill the coolant overflow bottle to the full line.
16. Start the engine.
17. Run the engine at 2,000-2,500 RPM until the engine reaches normal operating temperature.
18. Allow the engine to idle for 3 minutes.
19. Shut the engine OFF.
20. Allow the engine to cool.
21. Top off the coolant as necessary.
22. Inspect the concentration of the engine coolant, using the J 26568 .
23. Rinse away any excess coolant from the engine and the engine compartment.
24. Inspect the cooling system for leaks.
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5. 2009 Chevrolet Express - AWD | Express, Savana (VIN G/H) Service Manual | Engine | Engine Cooling |
Repair Instructions | Document ID: 2123824
Cooling System Draining and Filling (Vac N Fill)
Special Tools
Draining Procedure
Warning: With a pressurized cooling system, the coolant temperature in the radiator can be
considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the
surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil
instantaneously with explosive force. This will cause the solution to spew out over the engine, the
fenders, and the person removing the cap. Serious bodily injury may result.
1. Park the vehicle on a level surface.
2. Remove the coolant pressure cap.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Place a drain pan under the drain cock.
5. Open the radiator drain cock.
6. Drain the cooling system.
7. If a complete engine block drain is required, remove the engine block drain plug.
8. Inspect the coolant.
9. Follow the appropriate procedure based on the condition of the coolant.
Vac-N-Fill Procedure
Note: To prevent boiling of the coolant/water mixture in the vehicles cooling system, do not apply
vacuum to a cooling system above 49°C (120°F). The tool will not operate properly when the
coolant is boiling.
1. Install the J 42401 .
• J 26568 Coolant and Battery Tester
• GE-47716 Vac-N-Fill Coolant Refill Tool
• J 42401 Radiator Cap and Surge Tank Test Adapter
• Normal in appearance--Follow the filling procedure.
• Discolored--Follow the flush procedure. Refer to Flushing.
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6. 2. Attach the Van-N-Fill cap to the vehicles coolant fill port.
3. Attach the vacuum gage assembly to the Vac-N-Fill cap.
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7. 4. Attach the fill hose to the barb fitting on the vacuum gage assembly.
Ensure that the valve is closed.
Note: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water. Always use
more coolant than necessary. This will eliminate air from being drawn into the cooling
system.
5. Pour the coolant mixture into the graduated reservoir.
6. Place the fill hose in the graduated reservoir.
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9. Note: Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain
valve located on the bottom of the tank is closed.
7. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-
out area in the vacuum tank.
8. Attach the venture assembly to the vacuum tank.
9. Attach a shop air hose to the venture assembly.
Ensure the valve on the venture assembly is closed.
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10. 10. Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.
11. Clamp off the overflow hose.
12. Open the valve on the venture assembly. The vacuum gage will begin to rise and a hissing
noise will be present.
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11. 13. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-
26 in Hg).
Cooling hoses may start to collapse. This is normal due to vacuum draw.
14. To aid in the fill process, position the graduated reservoir above the coolant fill port.
15. Slowly open the valve on the vacuum gage assembly. When the coolant reaches the top of
the fill hose, close the valve. This will eliminate air from the fill hose.
16. Close the valve on the venture assembly.
17. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum
and monitor for vacuum loss.
If vacuum loss is observed, refer to Loss of Coolant.
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12. 18. Open the valve on the vacuum gage assembly. The vacuum gage will drop as coolant is
drawn into the system.
19. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and
repeat steps 11-17.
20. Remove the J 42401 .
21. Detach the Vac-N-Fill cap from the vehicles coolant fill port.
22. Add coolant to the system as necessary.
23. Inspect the concentration of the coolant mixture using J 26568 .
Note: After filling the cooling system, the extraction hose can be used to remove excess
coolant to achieve the proper coolant level.
24. Detach the vacuum hose form the vacuum gage assembly.
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