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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1003 (Engine Cooling System) >> Repair Instructions >> Thermostat Housing Crossover Replacement (6.6L (LB7) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostats with the seals.

    The thermostat with the vent valves goes toward the rear of the engine. Install with the vent valves towards the rear of the engine.

  2. Install the thermostat cover and gasket.
    3. Fig 1: View Of Thermostat Cover & Bolt
    GM660424Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the thermostat cover bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

  4. Install a new O-ring to the bypass pipe. Lubricate the O-ring with coolant.
  5. Install the bypass pipe to the thermostat housing crossover.
    6. Fig 2: View Of Bypass Pipe & O-Ring
    GM660428Courtesy of GENERAL MOTORS CORP.
  6. Install NEW thermostat housing gaskets.
  7. Install a NEW O-ring for the bypass pipe to the water pump.
  8. Install the thermostat housing with the bypass pipe.
    9. Fig 3: View Of Bypass Pipe & Thermostat Housing
    GM654526Courtesy of GENERAL MOTORS CORP.
  9. Install the bypass pipe to water pump bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

  10. Install the thermostat housing bolts and nuts.

    Tighten:  Tighten the bolts and nuts to 21 N.m (15 lb ft).

  11. Install the fuel line bracket and bolt.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

  12. Install the turbocharger coolant return pipe hose and clamps.
    13. Fig 4: View Of Turbocharger Coolant Feed Pipe, Bracket & Bolts
    GM699335Courtesy of GENERAL MOTORS CORP.
  13. Install the cooling fan pulley. Refer to Cooling Fan Pulley Replacement (6.6L (LB7) Engine) .
  14. Install a NEW O-ring seal to the heater inlet pipe.
  15. Install the heater inlet pipe to the thermostat housing crossover.
  16. Install the heater inlet pipe to thermostat housing crossover bolt.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

  17. Install the heater inlet pipe to fuel filter bolt.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

    18. Fig 5: View Of Heater Inlet Pipe, Thermostat Housing & Fuel Filter
    GM699325Courtesy of GENERAL MOTORS CORP.
  18. Install the generator bracket and bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    19. Fig 6: View Of Generator & Mounting Bracket
    GM669244Courtesy of GENERAL MOTORS CORP.
  19. Install the ribbed idler pulley and the bolt.

    Tighten:  Tighten the bolt to 43 N.m (32 lb ft).

  20. Install the heater outlet hose bracket bolt.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

  21. Install the fuel bleed valve and PCV oil separator bracket nuts to the generator bracket.

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

    22. Fig 7: View Of PCV Oil Separator & Bracket
    GM698198Courtesy of GENERAL MOTORS CORP.
  22. Install the power steering pump bracket and bolts.

    Tighten:  Tighten the bolts to 46 N.m (34 lb ft).

    23. Fig 8: View Of Power Steering Pump Bracket
    GM669241Courtesy of GENERAL MOTORS CORP.
  23. Install the water outlet. Refer to Water Outlet Tube Replacement (6.6L (LB7) Engine) .
  24. Position the generator positive cable.
  25. Install the generator positive cable in the clip on the engine front cover.
  26. Install the generator positive cable nut.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

  27. Install the battery positive cable junction block bracket and bolt to the power steering pump.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    28. Fig 9: View Of Upper Engine
    GM666693Courtesy of GENERAL MOTORS CORP.
  28. Connect the ECT sensor electrical connector.
  29. Connect the generator electrical connector (1).
    30. Fig 10: View of Generator Harness, Clip, A/C Refrigerant Switch, Dual Generator Harness Connector & A/C Compressor Clutch
    GM674573Courtesy of GENERAL MOTORS CORP.
  30. Position the A/C compressor.
  31. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    32. Fig 11: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  32. Connect the A/C cut out switch electrical connector.
  33. Connect the A/C compressor clutch electrical connector (5).
    34. Fig 12: View of Generator Harness, Clip, A/C Refrigerant Switch, Dual Generator Harness Connector & A/C Compressor Clutch
    GM674573Courtesy of GENERAL MOTORS CORP.
  34. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  35. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74)  or Fan Shroud Replacement - Upper (W/M74) .
  36. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  37. Connect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  38. Install the upper intake manifold cover.
  39. Install the upper intake manifold cover to the outlet duct.
  40. Tighten the outlet duct clamp at the upper intake manifold cover.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    41. Fig 13: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
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