Thermal Bypass Fitting Replacement 5.3L Engine w/RPO HP2

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Drain the cooling system and engine block. Refer to Cooling System Draining and Filling .
3. If necessary, disconnect the crankshaft position (CKP) sensor electrical connector.



4. Remove the thermal bypass hose bolt.
5. Reposition the thermal bypass hose clamp.
6. Remove the thermal bypass hose from the fitting.



7. Remove the thermal bypass fitting.

Notice: Refer to Fastener Notice in the Preface section.

Important: Check that the coolant hose sealing surfaces are clean and not damaged. Confirm that the hose clamp retention is adequate and the coolant hose is not deformed. Damaged components must be replaced to avoid coolant leaks.

1. Install the thermal bypass fitting.

Tighten
Tighten the fitting to 35 N·m (26 lb ft).




2. Install the thermal bypass hose to the fitting.
3. Position the thermal bypass hose clamp.
4. Install the thermal bypass hose bolt.

Tighten
Tighten the bolt to 10 N·m (89 lb in).




5. If necessary, connect the CKP sensor electrical connector.
6. Fill the cooling system and engine block. Refer to Cooling System Draining and Filling .
7. Lower the vehicle.