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 onto the water outlet.
Lightly lubricate the O-ring seal with coolant.
Install the water outlet.

Fig 1: View Of Water Outlet & Bolts

GM699329

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Install the water outlet tube bolts.
Tighten: Tighten the bolt to 21 N.m (15 lb ft).
Install the turbocharger bypass valve and washer.
Tighten: Tighten the valve to 60 N.m (44 lb ft).

Fig 2: View Of Turbocharger Bypass Valve & Washer

GM687052

Courtesy of GENERAL MOTORS CORP.

Connect the turbocharger coolant return hose to the turbocharger bypass valve.

Fig 3: View Of Turbocharger Inlet Coolant Hose

GM668427

Courtesy of GENERAL MOTORS CORP.

Fig 4: View Of Wiring Harness Bracket At Thermostat Housing

GM699749

Courtesy of GENERAL MOTORS CORP.

Install the bolt and wiring harness bracket to the thermostat housing.
Tighten: Tighten the bolt to 8 N.m (71 lb in).
Install the radiator inlet hose to the water outlet tube.

Fig 5: View Of Radiator Inlet Hose & Hose Clamps

GM674532

Courtesy of GENERAL MOTORS CORP.

Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
Install the upper intake manifold cover.
Install the upper intake manifold cover to the outlet duct.

Fig 6: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp

GM813243

Courtesy of GENERAL MOTORS CORP.

Tighten the outlet clamp at the upper intake manifold cover.
Tighten: Tighten the clamp to 6 N.m (53 lb in).