Engine Coolant Thermostat Housing Replacement 3.8L Engine

1. Open the radiator drain cock.
2. Partially drain the radiator.

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. Close the radiator drain cock.

Tighten
Tighten the radiator drain cock to 2 N·m (18 lb in).

4. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.



5. Remove the EGR valve outlet pipe bolt from the upper intake manifold.
6. Remove the EGR valve outlet pipe nut from the EGR valve adapter.
7. Remove the EGR valve pipe.



8. Reposition the inlet hose clamp at the water outlet.
9. Remove the inlet hose from the water outlet.



10. Remove the water outlet bolts (1).
11. Remove the water outlet (2).

1. Install the water outlet (2).

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.

2. Install the water outlet bolts (1).

Tighten
Tighten the water outlet bolts (1) to 27 N·m (20 lb ft).




3. Install the inlet hose to the water outlet.
4. Position the inlet hose clamp at the water outlet.



5. Install the EGR valve pipe.
6. Install the EGR valve outlet pipe nut from the EGR valve adapter.

Tighten
Tighten the EGR valve outlet pipe nut to 29 N·m (21 lb ft).

7. Install the EGR valve outlet pipe bolt from the upper intake manifold.

Tighten
Tighten the EGR valve outlet pipe bolt to 29 N·m (21 lb ft).




8. Connect the EGR valve electrical connector.
9. Add engine coolant.