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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 688 (Engine Cooling System) >> Repair Instructions >> Thermostat Housing Crossover Replacement (6.6L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new O-ring to the bypass pipe. Lubricate the O-ring with coolant.
  2. Install the bypass pipe to the thermostat housing crossover.
  3. Install new thermostat crossover gaskets.
  4. Install a new O-ring for the bypass pipe to the water pump.
  5. Install the thermostat crossover with the bypass pipe.
  6. Install the bypass pipe to water pump bolts. Tighten the bypass pipe to water pump bolts to 21 N.m (15 lb ft).
  7. Install the thermostat crossover bolts and nuts. Tighten the thermostat crossover bolts and nuts to 21 N.m (15 lb ft).
  8. Install the fuel line bracket and bolt. Tighten the fuel line bracket bolt to 21 N.m (15 lb ft).
  9. Install the hose and clamp from the turbocharger outlet coolant pipe to thermostat bypass pipe.
  10. Install the cooling fan pulley.
  11. Install a new O-ring seal to the heater pipe.
  12. Install the heater pipe to the thermostat housing crossover.
  13. Install the bolt retaining the heater pipe to the thermostat housing crossover. Tighten the heater pipe bolt to 21 N.m (15 lb ft).
  14. Install the bolt retaining the heater pipe to the fuel filter assembly. Tighten the heater pipe bracket bolt to 21 N.m (15 lb ft).
  15. Install the generator mounting bracket and bolts. Tighten the generator mounting bracket bolts to 50 N.m (37 lb ft).
  16. Install the ribbed idler pulley and the bolt. Tighten the idler puller bolt to 43 N.m (32 lb ft).
  17. Install the heater outlet hose bracket bolt. Tighten the bracket bolt to 21 N.m (15 lb ft).
  18. Install the nuts retaining the fuel bleed valve and PCV oil separator bracket from the generator mounting bracket. Tighten the bracket nuts to 25 N.m (18 lb ft).
  19. Install the power steering pump mounting bracket and bolts. Tighten the power steering pump mounting bracket bolts to 46 N.m (34 lb ft).
  20. Install the water outlet tube.
  21. Position the generator positive cable.
  22. Install the generator positive cable in the clip on the engine front cover.
  23. Install the generator positive cable and the retaining nut to the generator. Tighten the generator positive cable nut to 9 N.m (80 lb in).
  24. Install the battery positive cable junction block bracket and bolt to the power steering pump. Tighten the junction block bracket bolt to 9 N.m (80 lb in).
  25. Connect the generator electrical connector.
  26. Position the A/C compressor.
  27. Install the A/C compressor mounting bolts. Tighten the A/C compressor mounting bolts to 50 N.m (37 lb ft).
  28. Connect the A/C cut out switch electrical connector.
  29. Connect the A/C clutch electrical connector.
  30. Install the drive belt.
  31. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74)  or Fan Shroud Replacement - Upper (W/M74)  .
  32. Fill the engine coolant. Refer to Draining & Filling Cooling System .
  33. Connect the battery negative cable.
  34. Install the upper intake manifold cover.
  35. Install the upper intake manifold cover to the outlet duct.
  36. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten the clamp to 6 N.m (53 lb in).
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