GM Astro/Safari 1985-1996 Repair Guide




See Figures 1, 2, 3 and 4

Upper and lower radiator hoses along with the heater hoses should be checked for deterioration, leaks and loose hose clamps at least every 15,000 miles (24,000 km) or 12 months. It is also wise to check the hoses periodically in early spring and at the beginning of the fall or winter when you are performing other maintenance. A quick visual inspection could discover a weakened hose which might have left you stranded if it had remained unrepaired.

Whenever you are checking the hoses, make sure the engine and cooling system are both cold. Visually inspect for cracking, rotting or collapsed hoses, and replace as necessary. Run your hand along the length of the hose. If a weak or swollen spot is noted when squeezing the hose wall, the hose should be replaced.

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Fig. Fig. 1: The cracks developing along this hose are a result of age-related hardening

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Fig. Fig. 2: A hose clamp that is too tight can cause older hoses to separate and tear on either side of the clamp

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Fig. Fig. 3: A soft spongy hose (identifiable by the swollen section) will eventually burst and should be replaced

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Fig. Fig. 4: Hoses are likely to deteriorate from the inside if the cooling system is not periodically flushed


  1. Disconnect the negative battery cable for safety.
  3. Drain the cooling system to a level below the hose which is being removed. The entire system must be drained if the lower radiator hose is being disconnected from the radiator or engine.
  5. Loosen the hose clamps at each end of the hose.
  7. Working the hose back and forth, slide it off its connection.

When replacing the heater hoses, maintain a 11/2in. (38mm) clearance between the hose clip-to-upper control arm and between the rear overhead heater core lines-to-exhaust pipe.

  1. To install, reverse the removal procedures.

Draw the hoses tight to prevent sagging or rubbing against other components; route the hoses through the clamps as installed originally. Always make sure the hose clamps are beyond the component bead and placed in the center of the clamping surface before tightening them.