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.

Install a NEW O-ring seal to the thermostat.
Install the thermostat.

Fig 1: View Of Thermostat

GM42903

Courtesy of GENERAL MOTORS CORP.

Install the water outlet.

Fig 2: View Of Water Outlet

GM42895

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Install the water outlet studs.
Tighten: Tighten the studs to 25 N.m (18 lb ft).

Fig 3: View Of Water Outlet Studs

GM42901

Courtesy of GENERAL MOTORS CORP.

Install the inlet hose to the water outlet.
Position the inlet hose clamp at the water outlet.

Fig 4: View Of Radiator Inlet Hose & Thermostat Housing

GM367002

Courtesy of GENERAL MOTORS CORP.

Align the hinge clip with the lip on the throttle body.
In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.

Fig 5: View Of Air Cleaner Outlet Duct

GM489176

Courtesy of GENERAL MOTORS CORP.

Install the air cleaner adapter nut.

Fig 6: View Of Air Cleaner Adapter Nut

GM489179

Courtesy of GENERAL MOTORS CORP.

Install the PCV hose.

Fig 7: Positive Crankcase Ventilation (PCV) Hose

GM701705

Courtesy of GENERAL MOTORS CORP.

Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.

Fig 8: View Of Air Cleaner Outlet Duct Clamp

GM360851

Courtesy of GENERAL MOTORS CORP.

Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
Inspect the cooling system for leaks.