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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Cooling System) >> Repair Instructions >> Thermal Bypass Fitting Replacement (5.3L Engine w/RPO HP2) >> Installation Procedure

Installation Procedure

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.
NOTE: Refer to Fastener Notice in Cautions and Notices.
IMPORTANT: Check that the coolant hose sealing surfaces are clean and not damaged. Confirm that the hose clamp retention is adequate and the coolant hose is not deformed. Damaged components must be replaced to avoid coolant leaks.
  1. Install the thermal bypass fitting.

    Tighten:  Tighten the fitting to 35 N.m (26 lb ft).

    2. Fig 1: View Of Thermal Bypass Fitting
    GM1195699Courtesy of GENERAL MOTORS CORP.
  2. Install the thermal bypass hose to the fitting.
  3. Position the thermal bypass hose clamp.
  4. Install the thermal bypass hose bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    5. Fig 2: View Of Thermal Bypass Hose
    GM1195697Courtesy of GENERAL MOTORS CORP.
  5. If necessary, connect the CKP sensor electrical connector.
    6. Fig 3: View Of CKP Sensor Electrical Connector
    GM1236361Courtesy of GENERAL MOTORS CORP.
  6. Fill the cooling system and engine block. Refer to Draining and Filling Cooling System (with HP2) .
  7. Lower the vehicle.
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