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Thermostat Housing Crossover: Installation

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 Chevrolet RV Cutaway, and 2002 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the new gaskets. Install the thermostat housing crossover.
  2. Install the studs and bolts retaining the thermostat housing crossover to the engine. Tighten the bolts and studs to specifications. See TORQUE SPECIFICATIONS .
  3. Connect the radiator inlet hose to the thermostat housing crossover. Connect the by-pass hose to the thermostat housing crossover. Connect the heater hose to the thermostat housing crossover. Connect the electrical connector to the coolant temperature sensor.
  4. Install the A/C compressor. See COMPRESSOR under REMOVAL & INSTALLATION in MANUAL A/C HEATER SYSTEMS article.
  5. Install the stud in order to secure the fuel bleed valve at the thermostat housing. Install the nut in order to secure the dipstick tubes at the thermostat housing. Connect the battery negative cables to the battery terminals and tighten cables to specifications. See TORQUE SPECIFICATIONS .
  6. Refill the engine cooling system. See DRAINING & FILLING COOLING SYSTEM  under BLEEDING. Bleed the air from the engine cooling system by the following:
    1. Remove the cap from the surge tank.
    2. Remove the bleed screw, a slotted screw, from the top of the thermostat housing.
    3. Pour anti-freeze into the surge tank, and watch for anti-freeze from the bleed screw.
    4. When a constant flow of anti-freeze is reached, closed the bleed screw at the top of the thermostat housing.
    5. Continue to fill the surge tank to the proper level.
    6. Install the cap on the surge tank.
  7. Install the air intake duct to the turbocharger. Install the air cleaner assembly in the vehicle. Inspect the system for coolant leaks.
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