Engine Coolant Thermostat Replacement 4.3L

Removal Procedure

1. Remove the air cleaner and the duct assembly. Refer to Engine Controls.
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
3. Partially drain the coolant. Refer to Cooling System Draining and Filling .



4. Disconnect the radiator hose from the thermostat housing.



5. Remove the bolts attaching the thermostat housing to the thermostat.
6. Remove the thermostat housing.
7. Remove the thermostat.
8. Clean the gasket mating surfaces.

Installation Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold.
3. Install the bolts to the housing.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Connect the radiator hose to the thermostat housing.
5. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
6. Install the air cleaner and the duct. Refer to Engine Controls.

Important: In order to properly fill a system that has been completely drained, use the air bleed vents, located on the thermostat housing.

7. Refill the coolant. Refer to Cooling System Draining and Filling .
8. Inspect the thermostat housing and the gasket for coolant leaks.

Engine Coolant Thermostat Replacement 5.0L and 5.7L

Removal Procedure

1. Remove the air cleaner and the duct assembly. Refer to Engine Controls.
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
3. Partially drain the coolant. Refer to Cooling System Draining and Filling .



4. Disconnect the radiator hose from the thermostat housing.



5. Remove the bolts attaching the thermostat housing to the thermostat.
6. Remove the thermostat housing.
7. Remove the thermostat.
8. Clean the gasket mating surfaces.

Installation Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold.
3. Install the bolts to the housing.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




4. Connect the radiator hose to the thermostat housing.
5. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
6. Install the air cleaner and the duct. Refer to Engine Controls.

Important: In order to properly fill a system that has been completely drained, use the air bleed vents, located on the thermostat housing.

7. Refill the coolant. Refer to Cooling System Draining and Filling .
8. Inspect the thermostat housing and the gasket for coolant leaks.

Engine Coolant Thermostat Replacement 6.5L Diesel

Removal Procedure

1. Remove the air cleaner and the duct assembly. Refer to Engine Controls.
2. Remove the surge tank. Refer to Surge Tank (Diesel) .
3. Partially drain the coolant. Refer to Cooling System Draining and Filling .



4. Disconnect the radiator hose from the thermostat housing.



5. Remove the bolts attaching the thermostat housing to the thermostat.
6. Remove the thermostat housing.
7. Remove the thermostat.
8. Clean the gasket mating surfaces.

Installation Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold.
3. Install the bolts to the housing.

Tighten
Tighten the bolts to 42 N·m (31 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




4. Connect the radiator hose to the thermostat housing.
5. Install the surge tank. Refer to Surge Tank (Diesel) .
6. Install the air cleaner and the duct. Refer to Engine Controls.

Important: In order to properly fill a system that has been completely drained, use the air bleed vents, located on the thermostat housing.

7. Refill the coolant. Refer to Cooling System Draining and Filling .
8. Inspect the thermostat housing and the gasket for coolant leaks.

Engine Coolant Thermostat Replacement 7.4L

Removal Procedure

1. Remove the air cleaner and the duct assembly. Refer to Engine Controls.
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
3. Partially drain the coolant. Refer to Cooling System Draining and Filling .



4. Disconnect the radiator hose from the thermostat housing.



5. Remove the bolts attaching the thermostat housing to the thermostat.
6. Remove the thermostat housing.
7. Remove the thermostat.
8. Clean the gasket mating surfaces.

Installation Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Install the thermostat.
2. Install the thermostat housing to the intake manifold.
3. Install the bolts to the housing.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




4. Connect the radiator hose to the thermostat housing.
5. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
6. Install the air cleaner and the duct. Refer to Engine Controls.

Important: In order to properly fill a system that has been completely drained, use the air bleed vents, located on the thermostat housing.

7. Refill the coolant. Refer to Cooling System Draining and Filling .
8. Inspect the thermostat housing and the gasket for coolant leaks.