M Van (With or Without Air Conditioning)

1. Disconnect battery cable.

2. Drain engine of all coolant. Use a clean container and save the coolant for re-use.

3. Remove air intake and extension duct.

4. Remove oil fill tube.

5. Remove vacuum line bracket.

6. Remove upper radiator hose.

7. Remove generator belt.

8. Disconnect throttle cable at tile intake manifold.

9. Remove generator adjustment pivot bracket.

10. Remove generator front bracket.

11. Disconnect hose at thermostat housing.
12. Disconnect electrical harness at thermostat.

1. Items 13 thru 18 apply to trucks equipped with air conditioning.

13. Disconnect electrical harness at air conditioning compressor.

14. Remove air conditioning compressor belt.

15. Remove air conditioning compressor bracket.

16. Remove thermostat housing.

17. Insert the probe into the two cooling passages, Figure 1. The probe is to be inserted a minimum of 3.5 inches into the right coolant passage (passenger side of vehicle) and 4.5 inches into the left coolant passage (driver's side of vehicle). If this can be done, no further action is required. Proceed to step 18. If the probe will not slide into one or both passages even after several attempts, the cylinder head must be replaced. Refer to the Safari Service Manual X-8630 (Section 6A1-9) for removal and installation instructions, then proceed to step 18.

18. Clean the thermostat housing and cylinder head of all old sealant.

19. Apply sealant GM part number 1052915 or equivalent to the thermostat housing and install to the cylinder head.

20. Reverse steps 1-16 for parts reinstallation. Refill cooling system using original coolant. Top off coolant with GM part number 1052753 or equivalent mixed 50 percent with water

SPECIFICATIONS:
Belt tension (old belts):
Generator 300 N (67 lb.)
Air Conditioning 400 N (90 lb.)

Thermostat Housing
Bolts: 27 N-m (20 lb.ft.)

Generator Mounting Torque:
Top Bracket Bolt 27 N-m (20 lb.ft.)
Bottom Bracket Bolt 50 N-m (37 lb.ft.)
Nut at Back Brace 42 N-m (30 lb.ft.)

Compressor Mounting Bolts:
Front 43 N-m (32 lb.ft.)
Rear 30 N-m (22 lb.ft.)