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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 >> Thermostat Housing Crossover Replacement (6.6L (LLY) Engine) >> 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.
  1. If necessary, perform the following steps:
    1. Install NEW seals to the thermostats.
    2. Install the thermostats.
      3. NOTE: Refer to Fastener Notice in Cautions and Notices.
    3. Install the thermostat cover and bolts.

      Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

    4. Install a NEW O-ring seal to the thermostat bypass pipe.
    5. Install the thermostat bypass pipe to the thermostat housing.
  2. Install a NEW thermostat bypass pipe to water pump O-ring seal.
  3. Install the thermostat housing using NEW gaskets.
  4. Install the thermostat housing bolts and nuts

    Tighten:  Tighten the bolts/nuts to 21 N.m (15 lb ft).

    5. Fig 1: View Of Thermostat Housing
    GM1335441Courtesy of GENERAL MOTORS CORP.
  5. Install the water pump inlet pipe bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

    6. Fig 2: View Of Water Pump Inlet Pipe Bolts
    GM1335424Courtesy of GENERAL MOTORS CORP.
  6. Install the cooling fan pulley. Refer to Cooling Fan Pulley Replacement (6.6L (LLY) Engine) .
  7. Install the fuel line bracket bolt at the thermostat housing crossover.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

    8. Fig 3: View Of Fuel Pipe Bracket Bolt
    GM1335434Courtesy of GENERAL MOTORS CORP.
  8. Install the turbocharger coolant return pipe hose.
  9. Position the turbocharger coolant return pipe hose clamp.
    10. Fig 4: View Of Turbocharger Coolant Outlet Hose & Clamps
    GM1335429Courtesy of GENERAL MOTORS CORP.
  10. Install the EGR coolant pipe with O-ring seal to the crossover.
  11. Install the EGR coolant pipe bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  12. Position the EGR hose clamp at the EGR coolant pipe.
    13. Fig 5: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
    GM1335419Courtesy of GENERAL MOTORS CORP.
  13. Install the water outlet. Refer to Water Outlet Tube Replacement (6.6L (LLY) Engine) .
  14. Install the oil fill tube. Refer to Oil Fill Tube Replacement in Engine Mechanical - 6.6L (LLY).
  15. Position the generator bracket.
  16. Install the generator bracket bolts.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

    17. Fig 6: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  17. Install the idler pulley.

    Tighten:  Tighten the bolt to 43 N.m (32 lb ft).

  18. Install the heater outlet hose bracket bolt to the generator bracket.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

  19. Position the power steering pump bracket.
  20. Install the power steering pump bracket bolts.

    Tighten:  Tighten the bolt to 46 N.m (34 lb ft).

    21. Fig 7: View Of A/C Compressor & Power Steering Pump Bracket
    GM1334867Courtesy of GENERAL MOTORS CORP.
  21. Position the generator positive cable and the junction block bracket.
  22. Install the battery positive cable junction block to power steering pump bolt (1).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  23. Install the clip holding the positive cable to the engine front cover.
  24. Install the positive cable to the generator.
    25. Fig 8: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  25. Install the generator positive cable to generator nut.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

  26. Connect the ECT sensor electrical connector.
    27. Fig 9: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  27. Connect the generator electrical connector.
  28. Position the A/C compressor, with the hoses attached.
  29. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    30. Fig 10: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  30. Connect the A/C cut out switch electrical connector.
  31. Connect the A/C compressor clutch electrical connector (5).
    32. Fig 11: View of Generator Harness, Clip, A/C Refrigerant Switch, Dual Generator Harness Connector & A/C Compressor Clutch
    GM674573Courtesy of GENERAL MOTORS CORP.
  32. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L (LLY).
  33. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74)  or Fan Shroud Replacement - Upper (W/M74) .
  34. Connect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  35. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  36. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
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