Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 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.
NOTE: Refer to FASTENER NOTICE .
Install the water outlet tube bolts.
Tighten

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

Fig 1: Installing Water Outlet, Bolts & O-Ring Seal
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger bypass valve and washer.
Tighten

Tighten the valve to 60 N.m (44 lb ft).

Fig 2: Install Turbocharger Bypass Valve & Washer
Courtesy of GENERAL MOTORS CORP.
Connect the turbocharger coolant return hose to the turbocharger bypass valve.

Fig 3: Connect Turbocharger Coolant Return Hose
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).

Fig 4: Install Bolt & Wiring Harness Bracket
Courtesy of GENERAL MOTORS CORP.
Install the radiator inlet hose to the water outlet tube.
Fill the cooling system. Refer to Draining and Filling Cooling System .

Fig 5: Install Radiator Inlet Hose
Courtesy of GENERAL MOTORS CORP.
Install the upper intake manifold cover.
Install the upper intake manifold cover to the outlet duct.
Tighten the outlet clamp at the upper intake manifold cover.
Tighten

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

Fig 6: Install Upper Intake Manifold Cover
Courtesy of GENERAL MOTORS CORP.