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Thermostat Housing Cover: Installation

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 bypass pipe. Lubricate O-ring with coolant. Install bypass pipe to thermostat housing crossover. Install new thermostat crossover gaskets. Install a new O-ring for bypass pipe to water pump. Install thermostat crossover with bypass pipe.
  2. Install bypass pipe to water pump bolts. Install thermostat crossover bolts and nuts. Install fuel line bracket and bolt.
  3. Install hose and clamp from turbocharger outlet coolant pipe to thermostat bypass pipe. Install cooling fan pulley. Install a new O-ring seal to heater pipe. Install heater pipe to thermostat housing crossover. Install bolt retaining heater pipe to thermostat housing crossover. Install bolt retaining heater pipe to fuel filter assembly.
  4. Install generator mounting bracket and bolts. Install ribbed idler pulley and bolt. Install heater outlet hose bracket bolt.
  5. Install nuts retaining fuel bleed valve and PCV oil separator bracket from generator mounting bracket. Install power steering pump mounting bracket and bolts. Install water outlet tube.
  6. Position generator positive cable. Install generator positive cable in clip on engine front cover. Install generator positive cable and retaining nut to generator. Install battery positive cable junction block bracket and bolt to power steering pump. Connect generator electrical connector.
  7. Position A/C compressor. Install A/C compressor mounting bolts. Tighten A/C compressor mounting bolts to 37 ft. lbs. (50 N.m). Connect A/C cut-out switch electrical connector. Connect A/C clutch electrical connector. Install drive belt.
  8. Install upper fan shroud. See FAN SHROUD . Fill engine coolant. DRAINING & REFILLING COOLING SYSTEM . Connect battery negative cable. Install upper intake manifold sight shield.
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