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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 596 (Engine Cooling System) >> Repair Instructions >> Thermostat Housing Crossover Replacement (6.5L) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the new gaskets.
  2. Install the thermostat housing crossover.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  3. Install the studs and bolts retaining the thermostat housing crossover to the engine.

    Tighten 

    Tighten the bolts and studs to 47 N.m (35 ft lbs).

    Fig 1: Installing Studs & Bolts
    G01699555Courtesy of GENERAL MOTORS CORP.
  4. Connect the radiator inlet hose to the thermostat housing crossover.
    Fig 2: Connecting Radiator Inlet Hose
    G01699556Courtesy of GENERAL MOTORS CORP.
  5. Connect the by-pass hose to the thermostat housing crossover.
  6. Connect the heater hose to the thermostat housing crossover.
  7. Connect the electrical connector to the coolant temperature sensor.
  8. Install the A/C compressor. Refer to COMPRESSOR .
  9. Install the stud in order to secure the fuel bleed valve at the thermostat housing.
  10. Install the nut in order to secure the dipstick tubes at the thermostat housing.
  11. Connect the battery negative cables to the battery terminals.
    Fig 3: Connecting By-Pass Hose
    G01699557Courtesy of GENERAL MOTORS CORP.
  12. Refill the engine cooling system. Refer to Draining and Filling Cooling System .
  13. 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 a of 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.
  14. Install the air intake duct to the turbocharger.
  15. Install the air cleaner assembly in the vehicle. Refer to AIR CLEANER ASSEMBLY .
  16. Inspect the system for coolant leaks.
    Fig 4: Installing Air Intake Duct
    G01699558Courtesy of GENERAL MOTORS CORP.
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