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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 648 (Engine Cooling System) >> Repair Instructions >> Thermostat Housing Crossover Replacement (6.6L Engine) >> Inspection & Repair Procedure

Inspection & Repair 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. If required, remove the thermostat cover bolts.
  2. Remove the thermostat cover.
  3. Remove the thermostats with seals.
  4. Remove the thermostat seals.
  5. Remove the ECT sensor if replacing the thermostat housing crossover.
  6. Clean the water crossover.
  7. Clean the thermostat housing crossover mating surfaces.
  8. Inspect the thermostat housing crossover for cracks.
  9. Inspect the thermostat housing crossover mating surfaces for damage.
  10. Replace the thermostat housing crossover if any damage is found.
  11. Install the thermostats with the seals. The thermostat with the vent valves goes toward the rear of the engine. Install with the vent valves towards the rear of the engine.
  12. Install the thermostat cover and gasket.
  13. Install the thermostat cover bolts. Tighten the thermostat cover bolts to 21 N.m (15 lb ft).
  14. If removed, install the ECT sensor. Tighten the ECT sensor to 33 N.m (24 lb ft).
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