GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy Suburban - 4WD 🢒 Engine 🢒 Engine Mechanical - 8.1L 🢒 Water Crossover Installation

    Object Number: 635643 Size: SH
  1. Install the thermostat (3) with the seal into the coolant crossover (7).
  2. Install the water outlet (1).

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the water outlet bolts (2).

    4. Tighten
    Tighten the water outlet bolts to 30 N·m (22 lb ft).


    Object Number: 470698 Size: SH
  4. Place the coolant crossover gaskets and the coolant crossover in position.
  5. Install the coolant crossover bolts.

    6. Tighten
    Tighten the coolant crossover bolts to 50 N·m (37 lb ft).


    Object Number: 470692 Size: SH
  6. Install the thermostat bypass hose clamps onto the thermostat bypass hose.
  7. Install the thermostat bypass hose.

    8. Important: Properly position the bypass hose clamps to avoid water pump pulley interference.

  8. Position the thermostat bypass hose clamps.

    9. Object Number: 470789 Size: SH
  9. Install the drive belt tensioner.
  10. Install the drive belt tensioner bolts.

    11. Tighten
    Tighten the drive belt tensioner bolts to 50 N·m (37 lb ft).