Engine Coolant Thermostat Replacement 4.3L

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

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.

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.

3. Install the bolts to the housing.

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




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 Air Cleaner Outlet Resonator Replacement .
7. Refill the cooling system. Refer to Cooling System Draining and Filling .
8. Bleed the air from the cooling system.
9. Inspect the thermostat housing and the gasket for coolant leaks.

Engine Coolant Thermostat Replacement 6.6L (LLY/LBZ)

1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
2. Remove the intake manifold. Refer to Intake Manifold Tube Replacement .
3. Drain the cooling system. Refer to Cooling System Draining and Filling .



4. Compress the clamp and disconnect the radiator inlet hose from the thermostat housing.



5. Remove the fuel line bracket bolt and position the fuel line aside.



6. Compress the clamp and disconnect the turbocharger cooling inlet pipe from the thermostat housing.



7. Remove the 4 bolts and the thermostat housing.
8. Remove the thermostat and seals.

1. Inspect the thermostats for sticking, cracks, and/or leakage of wax.
2. Replace the thermostats if damage is found.
3. Clean the thermostat housing and thermostat housing cover sealing surfaces.

1. Install the thermostats and seals to the thermostat housing.

The rear thermostat (4) has 2 vent valves. Install the vent valves towards the rear of the engine.

Notice: Refer to Fastener Notice in the Preface section.




2. Position the thermostat housing and install the 4 bolts.

Tighten
Tighten the thermostat housing bolt to 21 N·m (15 lb ft).




3. Compress the clamp and connect the turbocharger cooling inlet pipe to the thermostat housing.



4. Position the fuel line to the thermostat housing and install the fuel line bracket bolt.

Tighten
Tighten the fuel line bracket bolt to 21 N·m (15 lb ft).




5. Compress the clamp and connect the radiator inlet hose to the thermostat housing.
6. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement .
7. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
8. Fill the cooling system. Refer to Cooling System Draining and Filling .

Engine Coolant Thermostat Replacement 6.6L (LMM)

1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
2. Remove the intake manifold. Refer to Intake Manifold Tube Replacement .
3. Drain the cooling system. Refer to Cooling System Draining and Filling .



4. Compress the clamp and disconnect the radiator inlet hose from the thermostat housing.



5. Disconnect two coolant temperature sensor electrical connectors (1).
6. Remove the fuel pipe bracket bolt (2).



7. Compress the clamp and disconnect the turbocharger cooling inlet pipe from the thermostat housing.



8. Remove the 4 bolts and the thermostat housing.
9. Remove the thermostat and seals.

1. Inspect the thermostats for sticking, cracks, and/or leakage of wax.
2. Replace the thermostats (1, 4) if damage is found.
3. Clean the thermostat housing and thermostat housing cover sealing surfaces.

1. Install the thermostats (1, 4) and seals to the thermostat housing.

The rear thermostat (4) has 2 vent valves. Install the vent valves towards the rear of the engine.

Notice: Refer to Fastener Notice in the Preface section.




2. Position the thermostat housing and install the 4 bolts.

Tighten
Tighten the thermostat housing bolt to 21 N·m (15 lb ft).




3. Compress the clamp and connect the turbocharger cooling inlet pipe to the thermostat housing.



4. Install the fuel pipe bracket bolt.

Tighten
Tighten the fuel pipe bracket bolt to 25 N·m (18 lb ft).

5. Connect two coolant temperature sensor electrical connectors (1).



6. Compress the clamp and connect the radiator inlet hose to the thermostat housing.
7. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement .
8. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
9. Fill the cooling system. Refer to Cooling System Draining and Filling .