- 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.
- Install the thermostat cover and gasket.
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.
- Install the thermostat cover bolts.
Tighten
Tighten the bolts to 21 N·m (15 lb ft).
- Install a new O-ring to the bypass pipe.
Lubricate the O-ring with coolant.
- Install the bypass pipe to the thermostat housing crossover.
- Install NEW thermostat housing gaskets.
- Install a NEW O-ring for the bypass pipe to the water pump.
- Install the thermostat housing with the bypass pipe.
- Install the bypass pipe to water pump bolts.
Tighten
Tighten the bolts to 21 N·m (15 lb ft).
- Install the thermostat housing bolts and nuts.
Tighten
Tighten the bolts and nuts to 21 N·m (15 lb ft).
- Install the fuel line bracket and bolt.
Tighten
Tighten the bolt to 21 N·m (15 lb ft).
- Install the turbocharger coolant return
pipe hose and clamps.
- Install the cooling fan pulley. Refer to
Cooling Fan Pulley Replacement
.
- Install a NEW O-ring seal to the heater
inlet pipe.
- Install the heater inlet pipe to the thermostat housing crossover.
- Install the heater inlet pipe to thermostat housing crossover bolt.
Tighten
Tighten the bolt to 21 N·m (15 lb ft).
- Install the heater inlet pipe to fuel filter bolt.
Tighten
Tighten the bolt to 21 N·m (15 lb ft).
- Install the generator bracket and bolts.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Install the ribbed idler pulley and the bolt.
Tighten
Tighten the bolt to 43 N·m (32 lb ft).
- Install the heater outlet hose bracket bolt.
Tighten
Tighten the bolt to 21 N·m (15 lb ft).
- Install the fuel bleed valve and PCV oil
separator bracket nuts to the generator bracket.
Tighten
Tighten the nuts to 25 N·m (18 lb ft).
- Install the power steering pump bracket
and bolts.
Tighten
Tighten the bolts to 46 N·m (34 lb ft).
- Install the water outlet. Refer to
Water Outlet Tube Replacement
.
- Position the generator positive cable.
- Install the generator positive cable in the clip on the engine front
cover.
- Install the generator positive cable nut.
Tighten
Tighten the nut to 9 N·m (80 lb in).
- Install the battery positive cable junction block bracket and bolt to
the power steering pump.
Tighten
Tighten the bolt to 9 N·m (80 lb in).
- Connect the ECT sensor electrical connector.
- Connect the generator electrical connector (1).
- Position the A/C compressor.
- Install the A/C compressor bolts.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Connect the A/C cut out switch electrical
connector.
- Connect the A/C compressor clutch electrical connector (5).
- Install the drive belt. Refer to
Drive Belt Replacement
in Engine Mechanical - 6.6L.
- Install the upper fan shroud. Refer to
Engine Coolant Fan Upper Shroud Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Connect the negative battery cables. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Install the upper intake manifold cover.
- Install the upper intake manifold cover to the outlet duct.
- Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten
Tighten the clamp to 6 N·m (53 lb in).