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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1032 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 2 Of 4)) >> Repair Instructions (Off-Vehicle - Part 2) >> Thermostat Housing Removal

Thermostat Housing Removal

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.
  1. Remove the thermostat cover bolts.
  2. Remove the thermostat cover.
  3. Remove the thermostats with seals.
    4. Fig 1: View Of Thermostat, Cover, Bolts & Seals
    GM798885Courtesy of GENERAL MOTORS CORP.
  4. Remove the heater pipe to thermostat housing bolt.
  5. Remove the heater pipe.
  6. Remove the heater pipe O-ring and discard.
  7. Remove the fuel pipe to thermostat housing bracket bolt.
    8. Fig 2: View Of Heater Pipe, O-Ring, Bracket & Bolt
    GM798886Courtesy of GENERAL MOTORS CORP.
  8. Remove the thermostat housing bolts and nuts from the left cylinder head.
  9. Remove the thermostat housing bolts and nuts from the right cylinder head.
  10. Remove the bypass pipe to water pump bolts.
  11. Loosen hose clamp and remove the turbocharger coolant outlet hose from the bypass pipe.
  12. Remove the thermostat housing with the bypass pipe.
  13. Remove the bypass pipe to water pump O-ring and discard.
    14. Fig 3: View Of Bypass Pipe To Water Pump Bolts & Thermostat Housing
    GM660426Courtesy of GENERAL MOTORS CORP.
  14. Remove the bypass pipe from the thermostat housing.
  15. Remove the O-ring from the bypass pipe and discard.
    16. Fig 4: View Of Bypass Pipe, Thermostat Housing & O-Ring
    GM660428Courtesy of GENERAL MOTORS CORP.
  16. Remove the turbocharger coolant outlet pipe bracket bolts.
  17. Remove the turbocharger coolant outlet pipe.
    18. Fig 5: View Of Turbocharger Coolant Outlet Pipe
    GM755218Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the oil pressure sensor connector.
  19. Remove the ground bolt from the left side of the block.
    20. Fig 6: View Of Ground Bolt (Left Side Of Engine Block)
    GM881728Courtesy of GENERAL MOTORS CORP.
  20. Remove the oil level sensor harness.
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