Engine Cooling System: Removal & Installation Chevrolet Silverado 3500

Removal Procedure

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .
2. Remove the SGCM radiator outlet hose (1) from the SGCM radiator (2). Refer to «Coolant Pipe Quick Connect Fitting - Starter/Generator Control Module»(ref-184167-S15713582732005082200000) .
3. Remove the ambient air temperature sensor (2) from the SGCM radiator bracket (3).
4. Disconnect the electrical connector from the SGCM cooling fan.
5. Remove the bolts (1) from the SGCM radiator (5).
6. Remove the SGCM radiator (5) from the radiator core support (4).
7. Remove the bolts (4) from the SGCM cooling fan (3).
8. Remove the SGCM cooling fan (3) from the SGCM radiator (2).

Installation Procedure

1. Install the SGCM cooling fan (3) to the SGCM radiator (2).
2. Install the bolts (4) to the SGCM cooling fan (3). Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the SGCM radiator (5) to the radiator core support (4).
4. Install the bolts (1) to the SGCM radiator (5). Tighten: Tighten the bolts to 9 N.m (80 lb in).
5. Connect the electrical connector to the SGCM cooling fan.
6. Install the ambient air temperature sensor (2) to the SGCM radiator bracket (3).
7. Install the SGCM radiator outlet hose (1) to the SGCM radiator (2). Refer to «Coolant Pipe Quick Connect Fitting - Starter/Generator Control Module»(ref-184167-S15713582732005082200000) .
8. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .
2. Raise the hood to the service position, and perform the following steps: Remove the ground strap from the hood. Remove the hood hinge bolts (1). Raise the hood until vertical. Install the hood hinge bolts until snug in the service position (2).
3. Reposition the SGCM coolant tank hose clamp (2) from the SGCM coolant tank (3).
4. Remove the SGCM coolant tank hose (1) from the SGCM coolant tank (3).
5. Reposition the SGCM pressure relief hose clamp from the SGCM pressure relief valve.
6. Remove the SGCM pressure relief hose from the SGCM pressure relief valve.
7. Remove the surge tank mounting bolts. Position the surge tank away from the SGCM module.
8. Remove the bolts (1) from the brace.
9. Reposition the SGCM coolant pump inlet hose clamp (1) from the SGCM coolant tank (2).
10. Remove the SGCM coolant pump inlet hose (3) from the SGCM coolant tank (2).
11. Remove the bolts from the SGCM coolant tank.
12. Reposition the SGCM coolant tank in order to access the SGCM rear bolt.
13. Remove the rear bolt (2) from the SGCM.
14. Remove the front bolt (3) from the SGCM.
15. Reposition the SGCM in order to remove the SGCM coolant tank.
16. Remove the SGCM coolant tank (2) from the vehicle.

1. Install the SGCM coolant tank (2) to the vehicle.
2. Position the SGCM coolant tank in order to install the SGCM rear bolt.
3. Install the rear bolt (2) to the SGCM. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
4. Install the front bolt (3) to the SGCM. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
5. Install the bolts to the SGCM coolant tank. Tighten: Tighten the bolts to 9 N.m (80 lb in).
6. Install the SGCM coolant pump inlet hose (3) to the SGCM coolant tank (2).
7. Position the SGCM coolant pump inlet hose clamp (1) to the SGCM coolant tank (2).
8. Install the bolts (1) to the brace. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
9. Install the surge tank.
10. Install the SGCM pressure relief hose to the SGCM pressure relief valve.
11. Position the SGCM pressure relief hose clamp to the SGCM pressure relief valve.
12. Install the SGCM coolant tank hose (1) to the SGCM coolant tank (3).
13. Position the SGCM coolant tank hose clamp (2) to the SGCM coolant tank (3).
14. Lower the hood from the service position, perform the following: Remove the hood hinge bolts from the service position (2). Lower the hood to the normal position. Install the hood hinge bolts (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
15. Install the ground strap to the hood.
16. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Reposition the starter/generator control module (SGCM) coolant tank hose clamp (2) from the SGCM coolant tank (3).
2. Remove the SGCM coolant tank hose (1) from the SGCM coolant tank (3).
3. Reposition the SGCM coolant tank hose clamp (4) from the SGCM (5).
4. Remove the SGCM coolant tank hose (1) from the SGCM (5).

1. Install the SGCM coolant tank hose (1) to the SGCM (5).
2. Position the SGCM coolant tank hose clamp (4) to the SGCM (5).
3. Install the SGCM coolant tank hose (1) to the SGCM coolant tank (3).
4. Position the SGCM coolant tank hose clamp (2) to the SGCM coolant tank (3).
5. Top off the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls - 5.3L.
3. Remove the push pin from the right side radiator air baffle.
4. Remove the bolts (2) from the SGCM coolant pump (1).
5. Reposition the SGCM coolant pump (1) from the radiator core support (3).
6. Disconnect the electrical connector (1) from the SGCM coolant pump (2).
7. Reposition the SGCM coolant pump outlet hose clamp (2) from the SGCM coolant pump (1).
8. Remove the SGCM coolant pump outlet hose (3) from the SGCM coolant pump (1).
9. Reposition the SGCM coolant pump inlet hose clamp (1) from the SGCM coolant pump (2).
10. Remove the SGCM coolant pump inlet hose (4) from the SGCM coolant pump (2).

1. Install the SGCM coolant pump inlet hose (4) to the SGCM coolant pump (2).
2. Position the SGCM coolant pump inlet hose clamp (1) to the SGCM coolant pump (2).
3. Position the SGCM coolant pump outlet hose clamp (2) to the SGCM coolant pump (1).
4. Install the SGCM coolant pump outlet hose (3) to the SGCM coolant pump (1).
5. Connect the electrical connector (1) to the SGCM coolant pump (2).
6. Position the SGCM coolant pump (1) to the radiator core support (3).
7. Install the bolts (2) to the SGCM coolant pump (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
8. Install the push pin to the right side radiator air baffle.
9. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls - 5.3L.
10. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .
2. Remove the surge tank. Refer to «Surge Tank Replacement»(ref-184167-S23934639362005082200000) .
3. Reposition the SGCM coolant pump inlet hose clamp (1) from the SGCM coolant tank (2).
4. Remove the SGCM coolant pump inlet hose (3) from the SGCM coolant tank (2).
5. Remove the bolts (2) from the SGCM coolant pump (1).
6. Reposition the SGCM coolant pump (1) from the radiator core support (3).
7. Open the coolant pump inlet hose clip (3) located on the frame rail.
8. Reposition the SGCM coolant pump inlet hose clamp (1) from the SGCM coolant pump (2).
9. Remove the SGCM coolant pump inlet hose (4) from the SGCM coolant pump (2).
10. Remove the SGCM coolant pump inlet hose (4) from the vehicle.

1. Install the SGCM coolant pump inlet hose (4) to the vehicle.
2. Install the SGCM coolant pump inlet hose (4) to the SGCM coolant pump (2).
3. Position the SGCM coolant pump inlet hose clamp (1) to the SGCM coolant pump (2).
4. Close the coolant pump inlet hose clip (3) located on the frame rail.
5. Position the SGCM coolant pump (1) to the radiator core support (3).
6. Install the bolts (2) to the SGCM coolant pump (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
7. Install the SGCM coolant pump inlet hose (3) to the SGCM coolant tank (2).
8. Position the SGCM coolant pump inlet hose clamp (1) to the SGCM coolant tank (2).
9. Install the surge tank. Refer to «Surge Tank Replacement»(ref-184167-S23934639362005082200000) .
10. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .
2. Remove the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
3. Remove the SGCM coolant pump outlet hose (5) from the clip (6).
4. Remove the SGCM coolant pump outlet hose (3) from the clip.
5. Reposition the SGCM coolant pump outlet hose clamp (2) from the SGCM coolant pump (1).
6. Remove the SGCM coolant pump outlet hose (3) from the SGCM coolant pump (1).
7. Remove the SGCM coolant pump outlet hose (3) from the vehicle.

1. Install the SGCM coolant pump outlet hose (3) to the vehicle.
2. Install the SGCM coolant pump outlet hose (3) to the SGCM coolant pump (1).
3. Position the SGCM coolant pump outlet hose clamp (2) to the SGCM coolant pump (1).
4. Install the SGCM coolant pump outlet hose (3) to the clip.
5. Install the SGCM coolant pump outlet hose (5) to the clip (6).
6. Install the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
7. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
2. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed.
3. Remove the starter/generator control module (SGCM) radiator hose from the SGCM radiator.

1. Hook one of the open ends of the retaining ring in one of the slots in the quick connector.
2. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots.
4. Install the SGCM radiator hose to the SGCM radiator quick connector fitting until a click is heard or felt. Pull back on the SGCM radiator hose to ensure a proper connection.

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .
2. Remove the SGCM radiator outlet hose (1) from the SGCM radiator (2). Refer to «Coolant Pipe Quick Connect Fitting - Starter/Generator Control Module»(ref-184167-S15713582732005082200000) .
3. Remove the ambient air temperature sensor (2) from the SGCM radiator bracket (3).
4. Disconnect the electrical connector from the SGCM cooling fan.
5. Remove the bolts (1) from the SGCM radiator (5).
6. Remove the SGCM radiator (5) from the radiator core support (4).
7. Remove the bolts (4) from the SGCM cooling fan (3).
8. Remove the SGCM cooling fan (3) from the SGCM radiator (2).

1. Install the SGCM cooling fan (3) to the SGCM radiator (2).
2. Install the bolts (4) to the SGCM cooling fan (3). Tighten: Tighten the bolts to 6 N.m (53 lb in).
3. Install the SGCM radiator (5) to the radiator core support (4).
4. Install the bolts (1) to the SGCM radiator (5). Tighten: Tighten the bolt to 9 N.m (80 lb in).
5. Connect the electrical connector to the SGCM cooling fan.
6. Install the ambient air temperature sensor (2) to the SGCM radiator bracket (3).
7. Install the SGCM radiator outlet hose (1) to the SGCM radiator (2). Refer to «Coolant Pipe Quick Connect Fitting - Starter/Generator Control Module»(ref-184167-S15713582732005082200000) .
8. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System - Starter/Generator Control Module»(ref-184167-S11938601932005082200000) .

1. Drain the starter/generator control module (SGCM) cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the SGCM radiator outlet hose (5) from the SGCM radiator (2). Refer to «Coolant Pipe Quick Connect Fitting - Starter/Generator Control Module»(ref-184167-S15713582732005082200000) .
3. Remove the SGCM radiator outlet hose (5) from the clip (4).
4. Remove the SGCM radiator outlet hose from the clip (3).
5. Remove the SGCM radiator outlet hose from the clip.
6. Reposition the SGCM radiator outlet hose clamp (2) from the SGCM (3).
7. Remove the SGCM radiator outlet hose (1) from the SGCM (3).
8. Remove the SGCM radiator outlet hose (1) from the vehicle.

1. Install the SGCM radiator outlet hose (1) to the vehicle.
2. Install the SGCM radiator outlet hose (1) to the SGCM (3).
3. Position the SGCM radiator outlet hose clamp (2) to the SGCM (3).
4. Install the SGCM radiator outlet hose to the clip.
5. Install the SGCM radiator outlet hose to the clip (3).
6. Install the SGCM radiator outlet hose (5) to the clip (4).
7. Install the SGCM radiator outlet hose (5) to the SGCM radiator (2). Refer to «Coolant Pipe Quick Connect Fitting - Starter/Generator Control Module»(ref-184167-S15713582732005082200000) .
8. Fill the SGCM cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
3. Remove the bolts from the engine shield.
4. Remove the engine shield from the vehicle.
5. Reposition the radiator outlet hose clamp (2) from the starter/generator stator cooler inlet pipe (3).
6. Remove the radiator outlet hose (1) from the starter/generator stator cooler inlet pipe (3).
7. Remove the bolt (4) from the starter/generator stator cooler inlet pipe (3).
8. Remove the starter/generator stator cooler inlet pipe (3) from the starter/generator stator (5).
9. Open the clip (2) at the starter/generator stator cooler inlet pipe (3).
10. Remove the starter/generator stator cooler inlet pipe (3) from the vehicle.

1. Install the starter/generator stator cooler inlet pipe (3) to the vehicle.
2. Install the starter/generator stator cooler inlet pipe (3) to the starter/generator stator (5).
3. Install the bolt (4) to the starter/generator stator cooler inlet pipe (3). Tighten: Tighten the bolt to 9 N.m (80 lb in).
4. Close the clip (2) at the starter/generator stator cooler inlet pipe (3).
5. Install the radiator outlet hose (1) to the starter/generator stator cooler inlet pipe (3).
6. Position the radiator outlet hose clamp (2) to the starter/generator stator cooler inlet pipe (3).
7. Install the engine shield to the vehicle.
8. Install the bolts to the engine shield. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
9. Lower the vehicle.
10. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184141-S05694939612005082200000) in Engine Control - 4.3 L, «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls - 4.8 L, 5.3 L, and 6.0 L or «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Control - 8.1 L.
3. Remove the surge tank overflow hose from the surge tank.
4. Disconnect the coolant level sensor electrical connector (3).
5. Reposition the surge tank inlet and outlet hose clamps.
6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank.
7. Reposition the surge tank inlet hose clamp from the surge tank.
8. Remove the surge tank inlet hose (1) from the surge tank.
9. Reposition the surge tank outlet hose clamp from the surge tank.
10. Remove the surge tank outlet hose (2) from the surge tank.
11. Remove the bolt from the surge tank.
12. Remove the nut from the surge tank.
13. Remove the surge tank.

1. Install the surge tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the bolt to the surge tank. Tighten: Tighten the bolt to 9 N.m (80 lb in).
3. Install the nut to the surge tank. Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Install the surge tank outlet hose (2) to the surge tank.
5. Position the surge tank outlet hose clamp to the surge tank.
6. Install the surge tank inlet hose (1) to the surge tank.
7. Position the surge tank inlet hose clamp to the surge tank.
8. Connect the coolant level sensor electrical connector (3).
9. Install the surge tank overflow hose.
10. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184141-S05694939612005082200000) in Engine Control - 4.3 L, «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls - 4.8 L, 5.3 L, and 6.0 L or «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Control - 8.1 L.
11. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Reposition the surge tank inlet hose clamp from the radiator.
3. Remove the surge tank inlet hose from the radiator.
4. Reposition the surge tank inlet hose clamp from the surge tank.
5. Remove the surge tank inlet hose (1) from the surge tank.

1. Install the surge tank inlet hose (1) to the surge tank.
2. Position the surge tank inlet hose clamp to the surge tank.
3. Install the surge tank inlet hose to the radiator.
4. Position the surge tank inlet hose clamp to the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed.
3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1).

1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector.
2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots.
4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Separate the MAF/IAT sensor assembly and the air inlet tube by loosening the hose clamp.
3. Disconnect the PCV hose from the air cleaner outlet duct.
4. Remove the air inlet tube and resonator retaining wing nut.
5. Remove the air inlet tube and resonator from the throttle body by pivoting the air inlet tube and resonator upward until the hinge clip releases from the lip on the throttle body.
6. Remove the radiator inlet hose from the support.
7. Remove the radiator inlet hose from the radiator.
8. Remove the radiator inlet hose from the thermostat housing.
9. Remove the radiator inlet hose.

1. Install the radiator inlet hose to the thermostat housing.
2. Install the radiator inlet hose to the radiator.
3. Install the radiator inlet hose to the support.
4. Align the hinge clip with the lip on the throttle body. Install the air inlet tube and resonator to the throttle body by pivoting the air inlet tube and resonator downward until the mounting stud is through the hole in the air inlet tube.
5. Install the resonator retaining wing nut.
6. Connect the PCV hose to the air cleaner outlet duct.
7. Connect the MAF/IAT sensor assembly harness connector.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass airflow/intake air temperature (MAF/IAT) sensor
3. Remove the radiator inlet hose clip from the outlet hose.
4. Remove the air cleaner outlet duct.
5. If necessary, remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
6. Remove the radiator vent inlet hose from the radiator inlet hose clips.
7. Reposition the inlet hose clamp at the radiator.
8. Remove the inlet hose clip from the fan shroud.
9. Remove the inlet hose from the radiator.
10. Reposition the inlet hose clamp at the water pump.
11. Remove the inlet hose from the water pump.

1. Install the inlet hose to the water pump.
2. Position the inlet hose clamp at the water pump.
3. Install the inlet hose to the radiator.
4. Position the inlet hose clamp at the radiator.
5. Install the inlet hose clip to the fan shroud.
6. Install the radiator vent inlet hose to the radiator inlet hose clips.
7. If necessary, install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
8. Install the air cleaner outlet duct.
9. Install the radiator inlet hose clip to the outlet duct.
10. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
11. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Move the hose clamps back on the radiator inlet hose.
3. Remove the radiator inlet hose from the radiator.
4. Remove the radiator inlet hose from the water outlet tube.

1. Install the radiator inlet hose to the water outlet tube.
2. Install the radiator inlet hose to the radiator.
3. Install the hose clamps on the radiator outlet hose.
4. Fill the engine coolant. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Reposition the inlet hose clamp at the radiator.
3. Remove the inlet hose from the radiator.
4. Reposition the inlet hose clamp at the water crossover.
5. Remove the inlet hose from the water crossover.

1. Install the inlet hose to the water crossover.
2. Position the inlet hose clamp at the water crossover.
3. Install the inlet hose to the radiator.
4. Position the inlet hose clamp at the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Separate the MAF/IAT sensor assembly and the air inlet tube by loosening the hose clamp.
2. Disconnect the PCV hose from the air cleaner outlet duct.
3. Remove the air inlet tube and resonator retaining wing nut.
4. Remove the air inlet tube and resonator from the throttle body by pivoting the air inlet tube and resonator upward until the hinge clip releases from the lip on the throttle body.
5. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
6. Remove the radiator outlet hose from the surge tank.
7. Remove the radiator outlet hose from the water pump.
8. Remove the radiator outlet hose from the radiator.
9. Remove the radiator outlet hose.

1. Install the radiator outlet hose to the radiator.
2. Install the radiator outlet hose to the water pump.
3. Install the radiator outlet hose to the surge tank.
4. Align the hinge clip with the lip on the throttle body. Install the air inlet tube and resonator to the throttle body by pivoting the air inlet tube and resonator downward until the mounting stud is through the hole in the air inlet tube.
5. Install the resonator retaining wing nut.
6. Connect the PCV hose to the air cleaner outlet duct.
7. Connect the MAF/IAT sensor assembly harness connector.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass airflow/intake air temperature (MAF/IAT) sensor
3. Remove the radiator inlet hose clip from the outlet duct.
4. Remove the air cleaner outlet duct.
5. Reposition the outlet hose clamp at the water pump.
6. Remove the outlet hose from the water pump.
7. Reposition the outlet hose clamp at the radiator.
8. Remove the outlet hose from the radiator.

1. Install the outlet hose to the radiator.
2. Position the outlet hose clamp at the radiator.
3. Install the outlet hose to the water pump.
4. Position the outlet hose clamp at the water pump.
5. Install the air cleaner outlet duct.
6. Install the radiator inlet hose clip to the outlet duct.
7. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the upper and lower fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) and «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
3. Remove the surge tank outlet hose (2) from the surge tank.
4. Remove the radiator outlet hose from the water pump.
5. Remove the heater outlet hose from the radiator outlet hose.
6. Remove the radiator outlet hose from the radiator.
7. Remove the radiator outlet hose clip retainers from the brackets.
8. Remove the radiator outlet hose from the vehicle.

1. Install the radiator outlet hose to the vehicle.
2. Install the radiator outlet hose and clamp to the radiator. Ensure the hose is positioned properly in order to prevent interference with the fan shroud.
3. Install the radiator outlet hose clip retainers to the brackets.
4. Install the surge tank outlet hose (2) to the surge tank.
5. Install the radiator outlet hose and clamp to the water pump.
6. Install the heater outlet hose to the radiator outlet hose.
7. Install the upper and lower fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) and «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
8. Fill the engine coolant. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the radiator outlet hose from the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-184167-S30999457252005082200000) .
3. Using the J 43181 disconnect the heater hoses from the heater core outlet. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
4. Reposition the surge tank outlet hose clamp at the surge tank.
5. Remove the surge tank outlet hose (2) from the surge tank.
6. Reposition the outlet hose clamp the water pump.
7. Remove the outlet hose from the water pump.

1. Install the outlet hose to the water pump.
2. Position the outlet hose clamp to the water pump.
3. Install the surge tank outlet hose (2) from the surge tank.
4. Position the surge tank outlet hose clamp to the surge tank.
5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
6. Install the radiator outlet hose to the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-184167-S30999457252005082200000) .
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) .
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass air flow (MAF)/intake air temperature (IAT) sensor
3. Remove the radiator inlet hose clip from the outlet duct.
4. Remove the air cleaner outlet duct.
5. Reposition the outlet hose clamp from the water pump.
6. Remove the outlet hose from the water pump.
7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
8. Remove the bolts from the engine shield.
9. Remove the engine shield from the vehicle.
10. Reposition the radiator outlet hose clamp (2) from the starter/generator stator cooler inlet pipe (3).
11. Remove the radiator outlet hose (1) from the starter/generator stator cooler inlet pipe (3).
12. Reposition the outlet hose clamp from the radiator.
13. Remove the outlet hose from the radiator.

1. Install the outlet hose to the radiator.
2. Position the outlet hose clamp to the radiator.
3. Install the radiator outlet hose (1) to the starter/generator stator cooler inlet pipe (3).
4. Position the radiator outlet hose clamp (2) to the starter/generator stator cooler inlet pipe (3).
5. Install the engine shield to the vehicle.
6. Install the bolts to the engine shield. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
7. Lower the vehicle.
8. Install the outlet hose to the water pump.
9. Position the outlet hose clamp to the water pump.
10. Install the air cleaner outlet duct.
11. Install the radiator inlet hose clip to the outlet duct.
12. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the screws to 7 N.m (62 lb in).
13. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Reposition the vent inlet hose clamp from the radiator.
3. Remove the vent inlet hose from the radiator.
4. Reposition the vent inlet hose clamp from the surge tank.
5. Remove the vent inlet hose from the surge tank.

1. Install the vent inlet hose to the surge tank.
2. Reposition the vent inlet hose clamp to the surge tank.
3. Install the vent inlet hose to the radiator.
4. Reposition the vent inlet hose clamp to the radiator.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe.
2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring.
3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings.
4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors.
5. Clean all of the components in a suitable solvent, and dry them with compressed air.
6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary.

1. Install a new retaining ring into each quick connector fitting.
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector.
3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots.
4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots.
5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection.
6. Snap the plastic cap onto the quick connect fitting.
7. Ensure that the plastic cap is fully seated against the fitting.
8. Ensure that no gap is present between the cap and the fitting.
9. Inspect and fill the engine oil to the proper level.

The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable.

1. Disconnect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .
2. If equipped with a 5.3L, or 6.0L engine, perform the following: Open the oil cooler hose clip located on the lower fan shroud. Remove the oil cooler hoses from the clip. Gently pull the oil cooler pipe fittings straight out from the radiator quick connect fittings.
3. If equipped with a 8.1L engine, remove the oil cooler hoses from the clip
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
5. If equipped, remove the engine shield bolts.
6. Remove the engine shield.
7. If equipped with a 5.3L, or 6.0L engine, perform the following: Remove the oil cooler hose bracket bolt (1). Remove the oil cooler hose adapter bolts (2). Remove the oil cooler hose assembly and gasket. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
8. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hose bracket bolt. Disconnect the quick connect fittings (1) at the engine. Remove the oil cooler hose assembly. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.

1. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hose assembly. Connect the quick connect fittings (1) at the engine. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices. Install the oil cooler hose bracket bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2. If equipped with a 5.3L, or 6.0L engine, perform the following: Install the oil cooler hose assembly and a new gasket. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the bolts to 12 N.m (106 lb in). Install the oil cooler hose bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. If equipped, install the engine shield.
4. Install the engine shield bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
5. Lower the vehicle.
6. If equipped with a 5.3L, or 6.0L engine, perform the following: Install the oil cooler hoses to the hose clip on the fan shroud. Snap the oil cooler hose clip shut.
7. If equipped with a 8.1L engine, install the oil cooler hoses to the clip.
8. Connect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .

The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable.

1. Disconnect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .
2. If equipped with a 5.3L or 6.0L engine, perform the following: Open the oil cooler hose clip located on the lower fan shroud. Remove the oil cooler hoses from the clip.
3. If equipped with a 8.1L engine, remove the oil cooler hoses from the clip.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
5. Place jack or utility stands at the rear of the vehicle.
6. If equipped, remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-184179-S32392415342005082200000) .
7. If equipped, remove the front differential carrier shield. Refer to «Shield Replacement»(ref-184180-S00879736072005082200000) .
8. Place an adjustable jack under the front differential carrier.
9. Remove the inner axle housing nuts and washers from the bracket.
10. Remove the differential carrier upper mounting bolt and nut.
11. Pivot the differential carrier forward and down on the lower mount bolt while it is being supported by the adjustable jack.
12. Secure the differential carrier to the jack.
13. Remove the differential carrier lower mounting bolt and nut.
14. Lower the jack 4 to 6 inches.
15. If equipped with a 5.3L or 6.0L engine, perform the following: Remove the oil cooler hose bracket bolt (1). Remove the oil cooler hose adapter bolts (2). Remove the oil cooler hose assembly and gasket. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.
16. If equipped with a 8.1L engine, perform the following: Remove the oil cooler hose bracket bolt. Disconnect the quick connect fittings (1) at the engine. Remove the oil cooler hose assembly. Discard the gasket. Inspect the fittings, connectors and cooler hoses for damage or distortion.

1. If equipped with a 8.1L engine, perform the following: Install the oil cooler hose assembly and a NEW gasket. Connect the quick connect fittings (1) at the engine. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices. Install the oil cooler hose bracket bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2. If equipped with a 5.3L or 6.0L engine, perform the following: Install the oil cooler hose assembly and a NEW gasket. Install the oil cooler hose adapter bolts (2). Tighten: Tighten the bolts to 12 N.m (106 lb in). Install the oil cooler hose bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Raise the jack in order to position the differential carrier.
4. Install the differential carrier lower mounting bolt and nut. Do not tighten the bolt at this time.
5. Pivot the differential carrier up and back on the lower mount bolt while it is being supported by the jack.
6. Install the differential carrier upper mounting bolt and nut. Do not tighten the bolt at this time.
7. Install the inner axle housing washers and nuts to the brackets. Tighten: The inner axle housing bolts to 100 N.m (75 lb ft). The upper and lower differential carrier bolts to 100 N.m (75 lb ft).
8. Remove the adjustable jack from under the front differential carrier.
9. If equipped, install the front differential carrier shield. Refer to «Shield Replacement»(ref-184180-S00879736072005082200000) .
10. If equipped, install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-184179-S32392415342005082200000) .
11. Remove the jack or utility stands from the rear of the vehicle.
12. Lower the vehicle.
13. If equipped with a 8.1L engine perform the following
14. Install the oil cooler hoses to the clip.
15. If equipped with a 5.3L or 6.0L engine, perform the following: Install the oil cooler hoses to the hose clip on the fan shroud. Snap the oil cooler hose clip shut.
16. Connect the engine oil cooler quick connect fittings. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .

1. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) or «Fan Shroud Replacement - Upper (W/HP2)»(ref-184167-S13444932982005082200000) .
2. Install the J 46406 to the fan clutch.
3. Remove the fan hub nut from the water pump in a counterclockwise rotation.
4. Remove the fan clutch bolts from the rear of the fan blade.
5. Separate the fan clutch from the fan blade.

1. Install the fan clutch onto the fan blade.
2. Install the fan clutch bolts Tighten: Tighten the bolts to 23 N.m (17 lb ft).
3. Install the fan assembly.
4. Install the J 46406 to the fan clutch. Tighten: Tighten the nut clockwise to 56 N.m (41 lb ft).
5. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) or «Fan Shroud Replacement - Upper (W/HP2)»(ref-184167-S13444932982005082200000) .

1. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) or «Fan Shroud Replacement - Upper (W/HP2)»(ref-184167-S13444932982005082200000) .
2. Install the J 46406 to the fan clutch.
3. Remove the fan hub nut from the water pump in a counterclockwise rotation.
4. Remove the fan clutch bolts from the rear of the fan blade.
5. Separate the fan clutch from the fan blade.

1. Install the fan clutch bolts from the rear of the fan blade.
2. Install the fan clutch bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).
3. Install the fan assembly.
4. Install the J 46406 to the fan clutch. Tighten: Tighten the nut clockwise to 56 N.m (41 lb ft).
5. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) or «Fan Shroud Replacement - Upper (W/HP2)»(ref-184167-S13444932982005082200000) .

1. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
2. Disconnect the camshaft position (CMP) sensor electrical connector (1).
3. Remove the fan pulley bolts/nuts.
4. Remove the fan pulley.
5. Remove the fan pulley spacer.

1. Install the fan pulley spacer.
2. Install the fan pulley.
3. Install the fan pulley bolts/nuts. Tighten: Tighten the bolts/nuts to 46 N.m (34 lb ft).
4. Connect the CMP sensor electrical connector (1).
5. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .

Scheme 10

1. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
2. Disconnect the camshaft position (CMP) sensor electrical connector.
3. Remove the fan pulley bolts/nuts.
4. Remove the fan pulley.

1. Install the fan pulley. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
2. Install the fan pulley bolts/nuts. Tighten: Tighten the bolts/nuts to 41 N.m (30 lb ft).
3. Connect the CMP sensor electrical connector (1).
4. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .

1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
5. Disconnect the turbocharger coolant return hose from the turbocharger bypass valve.
6. Remove the turbocharger bypass valve and washer.

1. Install the turbocharger bypass valve and washer. Tighten: Tighten the valve to 60 N.m (44 lb ft).
2. Connect the turbocharger coolant return hose to the turbocharger bypass valve.
3. Install the upper intake manifold sight shield.
4. Install the upper intake manifold cover to the outlet duct.
5. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
3. Reposition the coolant inlet hose clamp.
4. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.
5. Remove the turbocharger bypass valve and washer.

1. Install the turbocharger bypass valve and washer. Tighten: Tighten the valve to 60 N.m (44 lb ft).
2. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.
3. Position the coolant inlet hose clamp.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).

1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
5. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
6. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
7. Remove the outlet duct.
8. Loosen the charged air cooler outlet duct to intake hose clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
9. Remove the charged air cooler duct from the intake.
10. Remove the generator positive cable nut.
11. Remove the positive cable from the generator.
12. Disconnect the generator electrical connector (1).
13. Remove the ribbed idler pulley from the generator bracket.
14. Remove the generator bracket and position to the side. The generator does not require removal. The drive belt tensioner does not require removal.
15. Disconnect the fuel injection control module electrical connectors (2).
16. Remove the fuel line bolts.
17. Remove the fuel lines (2) from the fuel injection control module.
18. Using J 43181 , disconnect the inlet heater hose from the heater core inlet.
19. Remove the fuel injection control module wiring harness conduit from the heater pipe.
20. Remove the heater inlet pipe to fuel filter bolt.
21. Remove the heater inlet pipe to thermostat housing bolt.
22. Remove the heater inlet pipe with O-ring seal from the thermostat housing.
23. Remove the turbocharger coolant feed pipe bracket bolts.
24. Remove the turbocharger coolant return hose clamps and hose.
25. Disconnect the turbocharger coolant feed hose from the turbocharger.
26. Remove the turbocharger coolant feed pipe nut.
27. Remove the coolant feed pipe.
28. Disconnect the turbocharger coolant return hose from the turbocharger coolant bypass valve.
29. Disconnect the turbocharger coolant return hose from the turbocharger.

Scheme 11

1. Connect the turbocharger coolant return hose and clamp to the turbocharger coolant bypass valve.
2. Connect the turbocharger coolant return hose and clamp to the turbocharger.
3. Install the turbocharger coolant feed pipe.
4. Install the turbocharger coolant feed pipe nut. Tighten: Tighten the nut to 9 N.m (80 lb in).
5. Connect the turbocharger coolant feed hose and clamps to the turbocharger and the coolant pipe.
6. Install the turbocharger coolant return hose and clamps.
7. Install the turbocharger coolant feed pipe bracket bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
8. Install a NEW O-ring seal to the heater inlet pipe.
9. Install the heater inlet pipe to the thermostat housing.
10. Install the heater inlet pipe to thermostat housing bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
11. Install the heater inlet pipe to fuel filter bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
12. Connect the inlet heater hose to the heater inlet.
13. Install the fuel injection control module wiring harness conduit to the heater pipe.
14. Install the generator bracket and bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
15. Install the ribbed idler pulley and bolt. Tighten: Tighten the bolt to 43 N.m (32 lb ft).
16. Install the fuel lines (2) to the fuel injection control module.
17. Install the fuel line bolts. Tighten: Tighten the bolts to 35 N.m (26 lb ft).
18. Connect the fuel injection control module electrical connectors (2).
19. Install the generator positive cable and nut. Tighten: Tighten the nut to 9 N.m (80 lb in).
20. Connect the generator electrical connector (1).
21. Remove the tape from the turbocharger openings.
22. Install the charged air cooler outlet duct to the intake.
23. Align the mark on the duct (3) with the alignment mark on the intake.
24. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamps to 6 N.m (53 lb in).
25. Install the outlet duct to the turbocharger.
26. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
27. Install the outlet duct to the MAT/IAT sensor.
28. Tighten the outlet duct clamps at the turbocharger and the MAT/IAT sensor. Tighten: Tighten the clamps to 6 N.m (53 lb in).
29. Install the upper intake manifold cover.
30. Install the upper intake manifold cover to the outlet duct.
31. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
32. Fill the cooling. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
33. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
3. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
4. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
5. Reposition the turbocharger coolant inlet hose clamp at the bypass valve.
6. Remove the turbocharger coolant inlet hose banjo bolt (1).
7. Remove the inlet hose washer and inlet line.

1. Install the inlet hose washer and inlet line. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
2. Install the turbocharger coolant inlet hose banjo bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Position the turbocharger coolant inlet hose clamp at the bypass valve.
4. Remove the tape from the turbocharger openings.
5. Install the charged air cooler inlet duct connector (4) to the turbocharger.
6. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) in Engine Controls - 6.6L (LLY).
4. Loosen the charged air cooler outlet duct to intake hose clamp.
5. Remove the charged air cooler duct from the intake.
6. Remove the generator mounting bracket. Refer to «Generator Bracket Replacement (6.6L (LLY) Engine)»(ref-184144-S00721751172005082200000) in Engine Electrical.
7. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) in Engine Controls - 6.6L (LLY).
8. Disconnect the fuel injection control module electrical connectors.
9. Remove the upper fuel injection control module fuel line bolt.
10. Remove and discard the washer from the banjo fitting.
11. Reposition the hose clamp at the bypass pipe.
12. Remove the turbocharger coolant outlet hose from the bypass pipe.
13. Reposition the turbocharger coolant outlet hose clamp.
14. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.
15. Remove the turbocharger coolant outlet pipe bolt and nut.
16. If necessary, remove the turbocharger. Refer to «Turbocharger Replacement»(ref-184188-S32899997792005082200000) in Engine Mechanical - 6.6L (LLY).
17. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
18. If necessary, remove the coolant outlet pipe.

1. If necessary, install the coolant outlet pipe.
2. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger. Tighten: Tighten the bolt to 9 N.m (80 lb in).
3. If necessary, install the turbocharger. Refer to «Turbocharger Replacement»(ref-184188-S32899997792005082200000) in Engine Mechanical - 6.6L (LLY).
4. Install the turbocharger coolant outlet pipe bolt and nut. Tighten: Tighten the bolt/nut to 9 N.m (80 lb in).
5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
6. Position the turbocharger coolant outlet hose clamp.
7. Install the turbocharger coolant outlet hose to the bypass pipe.
8. Position the hose clamp at the bypass pipe.
9. Install a NEW washer to the banjo fitting.
10. Install the upper fuel injection control module fuel line bolt. Tighten: Tighten the bolt to 35 N.m (26 lb ft).
11. Connect the fuel injection control module electrical connectors.
12. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) in Engine Controls - 6.6L (LLY).
13. Install the generator mounting bracket. Refer to «Generator Bracket Replacement (6.6L (LLY) Engine)»(ref-184144-S00721751172005082200000) in Engine Electrical.
14. Install the charged air cooler duct to the intake.
15. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten: Tighten the clamp to 6 N.m (53 lb in).
16. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) in Engine Controls - 6.6L (LLY).
17. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
18. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
19. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) in Engine Controls - 6.6L (LLY).
3. Loosen the charged air cooler outlet duct to intake hose clamp.
4. Remove the charged air cooler outlet duct from the intake.
5. Remove the tie strap from the electrical harness.
6. Reposition the engine harness from the air inlet tube.
7. Remove the air inlet tube nuts.
8. Remove the air inlet tube.
9. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
10. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp.
11. Remove the EGR coolant pipe hose.
12. Remove the EGR coolant pipe bolts.
13. Remove the EGR coolant pipe.
14. Remove and discard the coolant pipe O-ring seal.

1. Install a NEW O-ring seal onto the coolant pipe. Lubricate the seal with engine coolant.
2. Install the EGR coolant pipe. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Install the EGR coolant pipe bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the EGR coolant pipe hose.
5. Position the EGR coolant pipe hose clamp.
6. Connect the ECT sensor electrical connector.
7. Install the air inlet tube.
8. Install the air inlet tube nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
9. Position the engine harness to the air inlet tube.
10. Install a NEW tie strap.
11. Install the charged air cooler outlet duct to the intake.
12. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten: Tighten the clamp to 6 N.m (53 lb in).
13. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) in Engine Controls - 6.6L (LLY).
14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Drain the cooling system and engine block. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) .
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.

Note. Refer to Fastener Notice in Cautions and Notices.

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 «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) .
7. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Drain the cooling system and engine block. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) .
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.

1. Install the thermal bypass hose to the fitting.
2. Position the thermal bypass hose clamp. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Install the thermal bypass hose bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. If necessary, connect the CKP sensor electrical connector.
5. Fill the cooling system and engine block. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) .
6. Lower the vehicle.

1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
5. Remove the radiator inlet hose from the water outlet tube.
6. Remove the bolt and wiring harness bracket at the thermostat housing.
7. Disconnect the turbocharger coolant return hose from the turbocharger bypass valve.
8. Remove the turbocharger bypass valve and sealing washer from the water outlet tube.
9. Remove the water outlet bolts.
10. Remove the water outlet.
11. Remove and discard the O-ring seal.

1. Install a NEW O-ring seal onto the water outlet.
2. Lightly lubricate the O-ring seal with coolant.
3. Install the water outlet.
4. Install the water outlet tube bolts. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
5. Install the turbocharger bypass valve and washer. Tighten: Tighten the valve to 60 N.m (44 lb ft).
6. Connect the turbocharger coolant return hose to the turbocharger bypass valve.
7. Install the bolt and wiring harness bracket to the thermostat housing. Tighten: Tighten the bolt to 8 N.m (71 lb in).
8. Install the radiator inlet hose to the water outlet tube.
9. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
10. Install the upper intake manifold cover.
11. Install the upper intake manifold cover to the outlet duct.
12. Tighten the outlet clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
3. Remove the radiator inlet hose from the water outlet tube.
4. Open the clip and remove the wiring harness branch from the bracket.
5. Remove the bolt and wiring harness bracket at the thermostat housing.
6. Remove the main engine electrical harness connector bolts.
7. Disconnect the barometric sensor electrical connector.
8. Disconnect the turbocharger vane position sensor electrical connector.
9. Remove the main electrical harness bracket bolts.
10. Remove the main electrical harness bracket.
11. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.
12. Remove the water outlet bolts.
13. Remove the water outlet.
14. Remove and discard the O-ring seal.

1. Install a NEW O-ring seal to the water outlet.
2. Lubricate the O-ring seal with clean engine coolant.
3. Install the water outlet.
4. Install the water outlet bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
5. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.
6. Install the main electrical harness bracket.
7. Install the main electrical harness bracket bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
8. Connect the turbocharger vane position sensor electrical connector.
9. Connect the barometric sensor electrical connector.
10. Install the main engine electrical harness connector bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
11. Install the wiring harness bracket and bolt to the thermostat housing. Tighten: Tighten the bolt to 10 N.m (89 lb in).
12. Install the wiring harness branch to the bracket and close the clip.
13. Install the radiator inlet hose to the water outlet tube.
14. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
15. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).

1. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (4.8, 5.3, and 6.0L Engines)»(ref-184167-S02611783232005082200000) or «Radiator Hose Replacement - Outlet (W/HP2)»(ref-184167-S34849659702005082200000) .
2. Remove the water pump inlet bolts.
3. Remove the water pump inlet and thermostat from the water pump.

1. Install the thermostat and thermostat housing to the water pump.
2. Install the thermostat housing bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
3. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (4.8, 5.3, and 6.0L Engines)»(ref-184167-S02611783232005082200000) or «Radiator Hose Replacement - Outlet (W/HP2)»(ref-184167-S34849659702005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Loosen the air cleaner outlet duct clamp at the mass airflow/intake air temperature (MAF/IAT) sensor.
3. Remove the positive crankcase ventilation (PCV) hose.
4. Remove the air cleaner adapter nut.
5. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body.
6. Reposition the inlet hose clamp at the water outlet.
7. Remove the inlet hose from the water outlet.
8. Remove the water outlet studs.
9. Remove the water outlet.
10. Remove the thermostat.
11. Clean the sealing surface of the water outlet.
12. Clean the sealing surface of the intake manifold.
13. Remove and discard the O-ring seal.

1. Install a NEW O-ring seal to the thermostat.
2. Install the thermostat.
3. Install the water outlet.
4. Install the water outlet studs. Tighten: Tighten the studs to 25 N.m (18 lb ft).
5. Install the inlet hose to the water outlet.
6. Position the inlet hose clamp at the water outlet.
7. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
8. Install the air cleaner adapter nut.
9. Install the PCV hose.
10. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
11. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
12. Inspect the cooling system for leaks.

1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) .
2. Remove the bolt for the fuel line bracket.
3. Remove the thermostat housing cover bolts.
4. Remove the thermostats and seals.

1. Install the thermostats and seals to the thermostat housing. The rear thermostat (4) has 2 vent valves. Install with the vent valves towards the rear of engine.
2. Install the thermostat housing cover with a NEW gasket. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the thermostat housing cover bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
4. Install the fuel line bracket bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
5. Install the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) .

1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) .
2. Remove the bolt for the fuel line bracket.
3. Remove the fuel line bracket.
4. Remove the thermostat housing cover bolts.
5. Remove the thermostat housing cover.
6. Remove the thermostats and seals.

1. Install the thermostats and seals to the thermostat housing. The rear thermostat (4) has 2 vent valves. Install with the vent valves towards the rear of engine.
2. Install the thermostat housing cover with a NEW gasket. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Install the thermostat housing cover bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
4. Install the fuel line bracket.
5. Install the fuel line bracket bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
6. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Reposition the inlet hose clamp at the water outlet.
3. Remove the inlet hose from the water outlet.
4. Remove the water outlet bolts (2).
5. Remove the water outlet (1).
6. Remove the thermostat (3).

1. Install the thermostat (3).
2. Install the water outlet (1). NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the water outlet bolts (2). Tighten: Tighten the bolts to 30 N.m (22 lb ft).
4. Install the inlet hose to the water outlet.
5. Position the inlet hose clamp at the water outlet.
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
5. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
6. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) .
7. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
8. Disconnect the air conditioning (A/C) compressor clutch electrical connector (5).
9. Disconnect the A/C cut out switch electrical connector.
10. Remove the A/C compressor bolts.
11. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
12. Remove the generator positive cable to generator nut.
13. Remove the positive cable from the generator.
14. Remove the clip holding the positive cable to the engine front cover.
15. Remove the battery positive cable junction block to power steering pump bolt.
16. Move the generator positive cable and the junction block bracket aside.
17. Disconnect the generator electrical connector (1).
18. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
19. Remove the power steering pump bracket and secure to the side. Do not remove the power steering pump from the bracket. The hoses and battery cables can remain on the power steering pump.
20. Remove the fuel bleed valve and positive crankcase ventilation (PCV) oil separator bracket bolt from the generator bracket.
21. Remove the heater outlet hose bracket bolt from the generator bracket.
22. Remove the ribbed idler pulley.
23. Remove the generator bracket and position to the side. The generator does not require removal. The drive belt tensioner does not require removal.
24. Remove the oil fill tube. Refer to «Oil Fill Tube Replacement»(ref-184191-S11543010562005082200000) in Engine Mechanical - 6.6L.
25. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) .
26. Remove the heater inlet pipe to fuel filter bolt.
27. Remove the heater inlet pipe with O-ring seal from the crossover.
28. Remove the turbocharger coolant return pipe clamps and hose.
29. Remove the fuel line bracket from the thermostat housing crossover.
30. Remove the cooling fan pulley. Refer to «Cooling Fan Pulley Replacement (6.6L (LB7) Engine)»(ref-184167-S15118344922005082200000) .
31. Remove the thermostat housing bolts and nuts from the left cylinder head.
32. Remove the thermostat housing bolts and nuts from the right cylinder head.
33. Remove the bypass pipe to water pump bolts.
34. Remove the thermostat housing with the bypass pipe.
35. Remove the bypass pipe to water pump O-ring.
36. Remove the bypass pipe from the thermostat housing.
37. Remove the O-ring from the bypass pipe.
38. Remove the thermostat cover bolts.
39. Remove the thermostat cover.
40. Remove the thermostats with seals.
41. Remove the thermostat seals.
42. If required, clean and inspect the thermostat housing. Refer to «Thermostat Housing Cleaning and Inspection»(ref-184233-S42667697902005082200000) in Engine Mechanical - 6.6L.

1. 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.
2. Install the thermostat cover and gasket.
3. Install the thermostat cover bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
4. Install a new O-ring to the bypass pipe. Lubricate the O-ring with coolant.
5. Install the bypass pipe to the thermostat housing crossover.
6. Install NEW thermostat housing gaskets.
7. Install a NEW O-ring for the bypass pipe to the water pump.
8. Install the thermostat housing with the bypass pipe.
9. Install the bypass pipe to water pump bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
10. Install the thermostat housing bolts and nuts. Tighten: Tighten the bolts and nuts to 21 N.m (15 lb ft).
11. Install the fuel line bracket and bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
12. Install the turbocharger coolant return pipe hose and clamps.
13. Install the cooling fan pulley. Refer to «Cooling Fan Pulley Replacement (6.6L (LB7) Engine)»(ref-184167-S15118344922005082200000) .
14. Install a NEW O-ring seal to the heater inlet pipe.
15. Install the heater inlet pipe to the thermostat housing crossover.
16. Install the heater inlet pipe to thermostat housing crossover bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
17. Install the heater inlet pipe to fuel filter bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
18. Install the generator bracket and bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
19. Install the ribbed idler pulley and the bolt. Tighten: Tighten the bolt to 43 N.m (32 lb ft).
20. Install the heater outlet hose bracket bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
21. 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).
22. Install the power steering pump bracket and bolts. Tighten: Tighten the bolts to 46 N.m (34 lb ft).
23. Install the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) .
24. Position the generator positive cable.
25. Install the generator positive cable in the clip on the engine front cover.
26. Install the generator positive cable nut. Tighten: Tighten the nut to 9 N.m (80 lb in).
27. 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).
28. Connect the ECT sensor electrical connector.
29. Connect the generator electrical connector (1).
30. Position the A/C compressor.
31. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
32. Connect the A/C cut out switch electrical connector.
33. Connect the A/C compressor clutch electrical connector (5).
34. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
35. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) .
36. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
37. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
38. Install the upper intake manifold cover.
39. Install the upper intake manifold cover to the outlet duct.
40. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
3. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
4. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) .
5. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184188-S09614751072005082200000) in Engine Mechanical - 6.6L (LLY).
6. Disconnect the air conditioning (A/C) compressor clutch electrical connector (5).
7. Disconnect the A/C cut out switch electrical connector.
8. Remove the A/C compressor bolts.
9. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.
10. Remove the generator positive cable to generator nut.
11. Remove the positive cable from the generator.
12. Remove the clip holding the positive cable to the engine front cover.
13. Remove the battery positive cable junction block to power steering pump bolt (1).
14. Move the generator positive cable and the junction block bracket aside.
15. Disconnect the generator electrical connector.
16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
17. Remove the power steering pump bracket bolts.
18. Reposition the power steering pump bracket and secure to the side. Do not remove the power steering pump from the bracket. The hoses and battery cables can remain on the power steering pump.
19. Remove the heater outlet hose bracket bolt from the generator bracket.
20. Remove the idler pulley.
21. Remove the generator bracket bolts.
22. Remove the generator bracket and position to the side. The generator does not require removal. The drive belt tensioner does not require removal.
23. Remove the oil fill tube. Refer to «Oil Fill Tube Replacement»(ref-184188-S23806693452005082200000) in Engine Mechanical - 6.6L (LLY).
24. Remove the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) .
25. Reposition the exhaust gas recirculation (EGR) hose clamp at the EGR coolant pipe.
26. Remove the EGR coolant pipe bolt.
27. Remove the EGR coolant pipe with O-ring seal from the crossover.
28. Reposition the turbocharger coolant return pipe hose clamp.
29. Remove the turbocharger coolant return pipe hose.
30. Remove the fuel line bracket bolt at the thermostat housing crossover.
31. Remove the cooling fan pulley. Refer to «Cooling Fan Pulley Replacement (6.6L (LLY) Engine)»(ref-184167-S17201509152005082200000) .
32. Remove the water pump inlet pipe bolts.
33. Remove the thermostat housing bolts and nuts.
34. Remove the thermostat housing, with the bypass pipe.
35. Remove and discard the thermostat bypass pipe to water pump O-ring seal.
36. Remove and discard the thermostat housing gaskets.
37. If necessary, perform the following steps: Remove the thermostat bypass pipe from the thermostat housing. Remove and discard the thermostat bypass pipe O-ring seal. Remove the thermostat cover bolts and cover. Remove the thermostats. Remove and discard the thermostat seals.
38. If required, clean and inspect the thermostat housing. Refer to «Thermostat Housing Cleaning and Inspection»(ref-184233-S42667697902005082200000) in Engine Mechanical - 6.6L (LLY).

1. If necessary, perform the following steps: Install NEW seals to the thermostats. Install the thermostats. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices. Install the thermostat cover and bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft). Install a NEW O-ring seal to the thermostat bypass pipe. Install the thermostat bypass pipe to the thermostat housing.
2. Install a NEW thermostat bypass pipe to water pump O-ring seal.
3. Install the thermostat housing using NEW gaskets.
4. Install the thermostat housing bolts and nuts Tighten: Tighten the bolts/nuts to 21 N.m (15 lb ft).
5. Install the water pump inlet pipe bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
6. Install the cooling fan pulley. Refer to «Cooling Fan Pulley Replacement (6.6L (LLY) Engine)»(ref-184167-S17201509152005082200000) .
7. Install the fuel line bracket bolt at the thermostat housing crossover. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
8. Install the turbocharger coolant return pipe hose.
9. Position the turbocharger coolant return pipe hose clamp.
10. Install the EGR coolant pipe with O-ring seal to the crossover.
11. Install the EGR coolant pipe bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
12. Position the EGR hose clamp at the EGR coolant pipe.
13. Install the water outlet. Refer to «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) .
14. Install the oil fill tube. Refer to «Oil Fill Tube Replacement»(ref-184188-S23806693452005082200000) in Engine Mechanical - 6.6L (LLY).
15. Position the generator bracket.
16. Install the generator bracket bolts. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
17. Install the idler pulley. Tighten: Tighten the bolt to 43 N.m (32 lb ft).
18. Install the heater outlet hose bracket bolt to the generator bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
19. Position the power steering pump bracket.
20. Install the power steering pump bracket bolts. Tighten: Tighten the bolt to 46 N.m (34 lb ft).
21. Position the generator positive cable and the junction block bracket.
22. Install the battery positive cable junction block to power steering pump bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
23. Install the clip holding the positive cable to the engine front cover.
24. Install the positive cable to the generator.
25. Install the generator positive cable to generator nut. Tighten: Tighten the nut to 9 N.m (80 lb in).
26. Connect the ECT sensor electrical connector.
27. Connect the generator electrical connector.
28. Position the A/C compressor, with the hoses attached.
29. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
30. Connect the A/C cut out switch electrical connector.
31. Connect the A/C compressor clutch electrical connector (5).
32. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184188-S09614751072005082200000) in Engine Mechanical - 6.6L (LLY).
33. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) .
34. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
35. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
36. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Accessory»(ref-184189-S30532579912005082200000) in Engine Mechanical - 8.1 L.
3. Reposition the inlet hose clamp at the water crossover.
4. Remove the inlet hose from the water crossover.
5. Reposition the heater inlet hose clamp at the water crossover.
6. Remove the heater inlet hose from the water crossover.
7. Reposition the bypass hose clamps at the water crossover and water pump.
8. Remove the bypass hose.
9. Remove the generator. Refer to «Generator Replacement (8.1L Engine)»(ref-184144-S35508253322005082200000) in Engine Electrical.
10. Remove the power steering pump. Refer to «Power Steering Pump Replacement (8.1L)»(ref-184156-S09574380352005082200000) in Power Steering System.
11. Remove the generator bracket bolts and nut.
12. Remove the generator bracket stud.
13. Remove the generator bracket.
14. Remove the water crossover bolts.
15. Remove the water crossover.
16. Remove and discard the water crossover gaskets.
17. If replacing the water crossover remove the following: Water outlet bolts (2) Water outlet (1) Thermostat (3)

1. If replacing the water crossover install the following: Thermostat (3) Water outlet (1) Water outlet bolts (2) Tighten: Tighten the bolts to 30 N.m (22 lb ft).
2. Install NEW water crossover gaskets.
3. Install the water crossover.
4. Install the water crossover bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the generator bracket.
6. Install the generator bracket stud. Tighten: Tighten the stud to 20 N.m (15 lb ft).
7. Install the generator bracket bolts and nut. Tighten: Tighten the bolts and nut to 50 N.m (37 lb ft).
8. Install the power steering pump. Refer to «Power Steering Pump Replacement (8.1L)»(ref-184156-S09574380352005082200000) in Power Steering System.
9. Install the generator. Refer to «Generator Replacement (8.1L Engine)»(ref-184144-S35508253322005082200000) in Engine Electrical.
10. Install the bypass hose.
11. Position the bypass hose clamps at the water crossover and water pump.
12. Install the heater inlet hose to the water crossover.
13. Position the heater inlet hose clamp at the water crossover.
14. Install the inlet hose to the water crossover.
15. Position the inlet hose clamp at the water crossover.
16. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement - Accessory»(ref-184189-S30532579912005082200000) in Engine Mechanical - 8.1 L.
17. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the coolant air bleed pipe bolts/studs (1).
3. Remove the coolant air bleed pipe (2) with gaskets (3).
4. Remove the coolant air bleed pipe cover bolts (1) and covers (2).
5. Remove the gaskets from the coolant air bleed pipe and covers.
6. Discard the gaskets.
7. Remove the coolant air bleed hose (1) from the pipe (2).

1. Install the coolant air bleed hose (1) onto the pipe (2).
2. Install the gaskets onto the coolant air bleed pipe and covers.
3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads. NOTE: Refer to Fastener Notice in Cautions and Notices.
4. Install the coolant air bleed pipe bolts/studs (1). Tighten: Tighten the bolts/studs to 12 N.m (106 lb in).
5. Install the coolant air bleed pipe covers (2) and bolts (1). Tighten: Tighten the bolts to 12 N.m (106 lb in).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Reposition the coolant air bleed hose clamp at the throttle body.
2. Remove the coolant air bleed hose from the throttle body.
3. Reposition the coolant air bleed hose clamp at the pipe.
4. Remove the coolant air bleed hose (1) from the pipe (2).

1. Install the coolant air bleed hose (1) to the pipe (2).
2. Position the coolant air bleed hose clamp at the pipe.
3. Install the coolant air bleed hose to the throttle body.
4. Position the coolant air bleed hose clamp at the throttle body.
5. Add engine coolant, if necessary.

1. Remove the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L (LB7) Engine)»(ref-184167-S16071792312005082200000) .
2. Remove the thermostat bypass pipe and O-ring seal from the thermostat housing.
3. Remove and discard the O-ring seal.
4. Clean the sealing surfaces of the bypass pipe.
5. Clean the water pump and the thermostat housing crossover sealing surfaces.

1. Install a new O-ring seal on the thermostat bypass pipe.
2. Lightly lubricate the O-ring seal with coolant.
3. Install a new O-ring seal for the bypass pipe to the water pump.
4. Install the bypass pipe in the thermostat housing.
5. Install the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L (LB7) Engine)»(ref-184167-S16071792312005082200000) .

1. Remove the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L (LLY) Engine)»(ref-184167-S02673552142005082200000) .
2. Remove the bypass pipe from the thermostat housing.
3. Remove and discard the O-ring seals from the bypass pipe and the water pump.
4. Clean the sealing surfaces of the bypass pipe.
5. If required, clean and inspect the bypass pipe and thermostat housing. Refer to «Thermostat Housing Cleaning and Inspection»(ref-184233-S42667697902005082200000) in Engine Mechanical - 6.6L (LLY).

1. Install a NEW O-ring seal onto the bypass pipe.
2. Install a NEW O-ring seal to the water pump.
3. Lubricate the O-ring seals with clean engine coolant.
4. Install the bypass pipe into the thermostat housing.
5. Install the thermostat housing. Refer to «Thermostat Housing Crossover Replacement (6.6L (LLY) Engine)»(ref-184167-S02673552142005082200000) .

1. Loosen the air cleaner outlet duct clamp at the mass airflow/intake air temperature sensor.
2. Remove the positive crankcase ventilation (PCV) hose.
3. Remove the air cleaner adapter nut.
4. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip release from the lip on the throttle body.
5. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
6. Remove the cooling fan. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) .
7. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184186-S18817359432005082200000) in Engine Mechanical - 4.3L.
8. Reposition the radiator outlet hose clamps at the surge tank and water pump.
9. Remove the radiator outlet hose from the surge tank.
10. Remove the radiator outlet hose from the water pump.
11. Reposition the water pump inlet hose clamps.
12. Remove the water pump inlet hose.
13. Using J 41240 , hold the water pump pulley, remove the water pump pulley bolts.
14. Remove the water pump bolts.
15. Remove the water pump.
16. Remove and discard the water pump gaskets.
17. Clean and inspect the water pump, if necessary. Refer to «Water Pump Cleaning and Inspection»(ref-184186-S39993798752005082200000) .

1. If reusing the old fasteners, apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts.
2. Install NEW water pump gaskets and the water pump. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the water pump bolts. Tighten: Tighten the bolts to 45 N.m (33 lb ft).
4. Using J 41240 , hold the water pump pulley, install the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Install the water pump inlet hose.
6. Position the water pump inlet hose clamps.
7. Install the radiator outlet hose to the water pump.
8. Install the radiator outlet hose to the surge tank.
9. Position the radiator outlet hose clamps at the surge tank and water pump.
10. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184186-S18817359432005082200000) in Engine Mechanical -4.3L.
11. Install the cooling fan. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
12. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
13. Install the air cleaner adapter nut.
14. Install the PCV hose.
15. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamps to 4 N.m (35 lb in).
16. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
17. Inspect the cooling system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass airflow/intake air temperature (MAF/IAT) sensor
3. Remove the radiator inlet hose clip from the outlet duct.
4. Remove the air cleaner outlet duct.
5. If necessary, remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
6. Remove the radiator vent inlet hose from the radiator hose clips.
7. Reposition the inlet hose clamp at the water pump.
8. Remove the inlet hose from the water pump.
9. Remove the fan blade. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) .
10. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S31770338242005082200000) or «Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2)»(ref-184187-S10400935602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
11. Reposition the outlet hose clamp at the water pump.
12. Remove the outlet hose from the water pump.
13. Reposition the surge tank outlet hose clamp at the water pump.
14. Remove the surge tank outlet hose from the water pump.
15. Reposition the heater inlet hose clamp at the water pump.
16. Remove the heater inlet hose from the water pump.
17. Remove the water pump bolts.
18. Remove the water pump and gaskets.
19. Discard the water pump gaskets.

1. Install the water pump and NEW gaskets. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the water pump bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts a final pass to 30 N.m (22 lb ft).
3. Install the heater inlet hose to the water pump.
4. Position the heater inlet hose clamp at the water pump.
5. Install the surge tank outlet hose to the water pump.
6. Position the surge tank outlet hose clamp at the water pump.
7. Install the outlet hose to the water pump.
8. Position the outlet hose clamp at the water pump.
9. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S31770338242005082200000) or «Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2)»(ref-184187-S10400935602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
10. Install the fan blade. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) .
11. Install the inlet hose to the water pump.
12. Position the inlet hose clamp at the water pump.
13. Install the engine vent inlet hose to the radiator hose clips.
14. If necessary, install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0 L.
15. Install the air cleaner outlet duct.
16. Install the radiator inlet hose clip to the outlet duct.
17. Tighten the air cleaner outlet duct clamps at the following locations: Throttle body MAF/IAT sensor Tighten: Tighten the clamps to 7 N.m (62 lb in).
18. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Remove the left fender wheelhouse inner panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
2. Drain the engine coolant and the engine block. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
3. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L (LB7) Engine)»(ref-184167-S16071792312005082200000) .
4. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
5. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-184191-S10379319062005082200000) in Engine Mechanical - 6.6 L.
6. Remove the oil cooler inlet pipe to water pump nuts.
7. Remove the engine wiring harness retainer from the inner stud.
8. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths.
9. Remove the water pump.
10. Remove the water pump outlet pipe gasket.
11. If required, clean and inspect the water pump. Refer to «Water Pump Cleaning and Inspection»(ref-184233-S05272795872005082200000) in Engine Mechanical - 6.6L.

1. Lubricate the water pump O-ring with engine oil.
2. Install the water pump.
3. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
4. Install the water pump to oil cooler inlet pipe gasket.
5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud.
6. Install the water pump to oil cooler inlet pipe nuts. Tighten: Tighten the nuts to 21 N.m (1 lb ft).
7. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L (LB7) Engine)»(ref-184167-S16071792312005082200000) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-184191-S10379319062005082200000) in Engine Mechanical - 6.6 L.
9. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
10. Fill the engine with coolant. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
11. Install the left fender wheelhouse inner panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.

1. Remove the left wheelhouse inner panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
2. Remove the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement (6.6L (LLY))»(ref-184167-S39309477262005082200000) .
3. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-184188-S06500011492005082200000) in Engine Mechanical - 6.6L (LLY).
4. Remove the water pump to engine coolant pipe nuts.
5. Remove the engine wiring harness retainer from the inner stud.
6. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths.
7. Remove the water pump.
8. Remove and discard the water pump O-ring and coolant pipe gasket.
9. If required, clean and inspect the water pump. Refer to «Water Pump Cleaning and Inspection»(ref-184233-S05272795872005082200000) in Engine Mechanical - 6.6L (LLY).

1. Lubricate the water pump O-ring with engine oil.
2. Install the engine coolant pipe gasket and water pump O-ring.
3. Install the water pump. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
4. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud.
6. Install the water pump to engine coolant pipe nuts. Tighten: Tighten the nuts to 21 N.m (15 lb ft).
7. Install the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement (6.6L (LLY))»(ref-184167-S39309477262005082200000) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(ref-184188-S06500011492005082200000) in Engine Mechanical - 6.6L (LLY).
9. Install the left wheelhouse inner panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-184189-S41162859002005082200000) in Engine Mechanical - 8.1 L.
3. Remove the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
4. Reposition the outlet hose clamp at the water pump.
5. Remove the outlet hose from the water pump.
6. Reposition the bypass hose clamps at the water pump and water crossover.
7. Remove the bypass hose.
8. Remove the water pump bolts.
9. Remove the water pump.
10. Remove and discard the water pump gaskets.

1. Place NEW water pump gaskets into place.
2. Install the water pump. NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the water pump bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the bypass hose.
5. Position the bypass hose clamps at the water pump and water crossover.
6. Install the outlet hose to the water pump.
7. Position the outlet hose clamp at the water pump.
8. Install the fan clutch. Refer to «Fan Clutch Replacement»(ref-184167-S35137668432005082200000) .
9. Install the drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-184189-S41162859002005082200000) in Engine Mechanical - 8.1 L.
10. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Remove the water pump. Refer to «Water Pump Replacement (6.6L (LB7) Engine)»(ref-184167-S05387915112005082200000) .
2. Remove the oil cooler inlet/water pump outlet pipe from the engine oil cooler.
3. Remove and discard the O-ring seal.
4. Remove the gasket and clean the sealing surface.

1. Install a new O-ring seal on the water pump outlet pipe.
2. Lightly lubricate the O-ring seal with engine oil.
3. Install the oil cooler inlet/water pump outlet pipe in the engine oil cooler.
4. Install a NEW oil cooler inlet pipe to water pump gasket.
5. Install the water pump. Refer to «Water Pump Replacement (6.6L (LB7) Engine)»(ref-184167-S05387915112005082200000) .

1. Remove the water pump. Refer to «Water Pump Replacement (6.6L (LLY))»(ref-184167-S24674729852005082200000) .
2. Remove the engine coolant pipe.
3. Remove and discard the coolant pipe O-ring seal.

1. Install a NEW O-ring seal onto the coolant pipe.
2. Lubricate the O-ring seal with engine coolant.
3. Install the engine coolant pipe.
4. Install the water pump. Refer to «Water Pump Replacement (6.6L (LLY))»(ref-184167-S24674729852005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Reposition the front heater inlet hose clamp (4) from the auxiliary water pump (1).
3. Remove the front heater inlet hose (6) from the auxiliary water pump (1).
4. Reposition the rear heater inlet hose clamp (2) from the auxiliary water pump (1).
5. Remove the rear heater inlet hose (3) from the auxiliary water pump (1).
6. Remove the heater outlet hose from the clip.
7. Disconnect the electrical connector (1) from the auxiliary water pump (2).
8. Remove the nuts (4) from the auxiliary water pump bracket (1).
9. Remove the auxiliary water pump (1) from the vehicle.
10. Remove the clips (2) from the auxiliary water pump bracket (1).
11. Remove the auxiliary water pump (3) from the auxiliary water pump bracket (1).

1. Install the auxiliary water pump (3) to the auxiliary water pump bracket (1).
2. Install the clips (2) to the auxiliary water pump bracket (1).
3. Install the auxiliary water pump (1) to the vehicle.
4. Install the nuts (4) to the auxiliary water pump bracket (1). Tighten: Tighten the nuts to 9 N.m (80 lb in).
5. Connect the electrical connector (1) to the auxiliary water pump (2).
6. Install the heater outlet hose to the clip.
7. Install the rear heater inlet hose (3) to the auxiliary water pump (1).
8. Position the rear heater inlet hose clamp (2) to the auxiliary water pump (1).
9. Install the front heater inlet hose (6) to the auxiliary water pump (1).
10. Position the front heater inlet hose clamp (4) to the auxiliary water pump (1).
11. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the radiator drain cock.

1. Install the radiator drain cock.
2. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Loosen the air cleaner outlet duct clamps from the throttle body.
2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
3. Remove the air cleaner outlet duct.
4. If equipped remove the throttle body heater hose retainer from the fan shroud.
5. If equipped remove the inlet radiator hose retainer from the fan shroud.
6. Remove the fan shroud retainers.
7. Remove the fan shroud bolts
8. Remove the upper fan shroud.

1. Install the upper fan shroud. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the fan shroud bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the fan shroud retainers.
4. If equipped install the inlet radiator hose retainer to the fan shroud
5. If equipped install the throttle body heater hose retainer to the fan shroud.
6. Install the air cleaner outlet duct.
7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten: Tighten the clamp screw to 7 N.m (62 lb in).
8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp screw to 7 N.m (62 lb in).

1. Loosen the air cleaner outlet duct clamps from the throttle body.
2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor.
3. Remove the air cleaner outlet duct.
4. Remove the A/C line retainer from the fan shroud.
5. Remove the engine harness clip from the PCM cover.
6. Remove the TCM cover bolts.
7. Remove TCM cover from the fan shroud.
8. Loosen the TCM electrical connector bolts.
9. Disconnect the TCM electrical connectors (1).
10. Remove the TCM and cover.
11. Remove the fan shroud retainers.
12. Remove the fan shroud bolts
13. Remove the upper fan shroud.

1. Install the upper fan shroud. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the fan shroud bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the fan shroud retainers.
4. Connect the TCM electrical connectors (1).
5. Install the TCM and cover.
6. Tighten the TCM electrical connector bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
7. Install the TCM cover to the fan shroud.
8. Install the TCM cover bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
9. Install the engine harness clip to the PCM cover.
10. Install the A/C line retainer to the fan shroud.
11. Install the air cleaner outlet duct.
12. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten: Tighten the clamp screws to 7 N.m (62 lb in).
13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten: Tighten the clamp screws to 7 N.m (62 lb in).

1. Loosen the air cleaner outlet duct clamps from the throttle body.
2. Loosen the air cleaner outlet duct clamps from the mass air flow (MAF) sensor.
3. Remove the air cleaner outlet duct.
4. Remove the hybrid control module (HCM). Refer to «Hybrid Control Module (HCM) Replacement (5.3L Engine w/RPO HP2)»(ref-184144-S23866655632005082200000) in Engine Electrical.
5. Remove the throttle body heater hose retainer from the fan shroud.
6. Remove the inlet radiator hose retainer from the fan shroud.
7. Remove the fan shroud retainers.
8. Remove the fan shroud bolts.
9. Remove the upper fan shroud.

1. Install the upper fan shroud.
2. Install the fan shroud bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the fan shroud retainers.
4. Install the inlet radiator hose retainer to the fan shroud.
5. Install the throttle body heater hose retainer to the fan shroud.
6. Install the HCM. Refer to «Hybrid Control Module (HCM) Replacement (5.3L Engine w/RPO HP2)»(ref-184144-S23866655632005082200000) in Engine Electrical.
7. Install the air cleaner outlet duct.
8. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten: Tighten the screw to 7 N.m (62 lb in).
9. Tighten the air cleaner outlet duct clamp at the MAF sensor. Tighten: Tighten the screw to 7 N.m (62 lb in).

Scheme 12

1. Remove the cooling fan. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) .
2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud.
3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator.

1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down.
2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud.
3. Install the cooling fan. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Position the inlet hose clamp from the radiator.
3. Remove the inlet hose from the radiator.
4. Position the outlet hose clamp from the radiator.
5. Remove the radiator outlet hose from the radiator.
6. Remove the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
7. Position the radiator vent inlet hose clamp from the radiator.
8. Remove the vent inlet hose from the radiator.
9. Remove the engine oil cooler lines from the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .
10. Remove the transmission oil cooler lines from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) in Transmission 4L80E or «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) in Transmission 4L60E.
11. Remove the radiator bolts.
12. Remove the radiator from the vehicle.

1. Install the radiator to the vehicle. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the radiator bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the engine oil cooler lines to the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .
4. Install the transmission oil cooler lines to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) in Transmission 4L80E or «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) in Transmission 4L60E.
5. Install the radiator vent inlet hose to the radiator.
6. Reposition the radiator vent inlet hose clamp to the radiator.
7. Install the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
8. Install the outlet hose to the radiator.
9. Reposition the outlet hose clamp to the radiator.
10. Install the inlet hose to the radiator.
11. Reposition the inlet hose clamp to the radiator.
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Reposition the inlet hose clamp from the radiator.
3. Remove the inlet hose from the radiator.
4. Remove the radiator outlet hose from the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-184167-S30999457252005082200000) .
5. Remove the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Controls - 8.1L.
7. Remove the push pin from the air cleaner adapter (2).
8. Remove the bolts from the air cleaner adapter (2).
9. Remove the air cleaner adapter (2) from the vehicle.
10. Position the radiator vent inlet hose clamp from the radiator.
11. Remove the vent inlet hose from the radiator.
12. Remove the engine oil cooler lines from the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .
13. Remove the transmission oil cooler lines from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) in Automatic Transmission - 4L80-E/4L85-E.
14. Remove the radiator bolts.
15. Remove the radiator from the vehicle.

1. Install the radiator to the vehicle. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the radiator bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the engine oil cooler lines to the radiator. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(ref-184167-S27470847082005082200000) .
4. Install the transmission oil cooler lines to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) in Automatic Transmission - 4L80-E/4L85-E.
5. Install the air cleaner adapter (2) to the vehicle.
6. Install the bolts to the air cleaner adapter (2). Tighten: Tighten the bolts to 9 N.m (80 lb in).
7. Install the push pin to the air cleaner adapter (2).
8. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184137-S32230603092005082200000) in Engine Controls - 8.1L.
9. Install the radiator vent inlet hose to the radiator.
10. Reposition the radiator vent inlet hose clamp to the radiator.
11. Install the lower fan shroud. Refer to «Fan Shroud Replacement - Lower»(ref-184167-S15070820552005082200000) .
12. Install the outlet hose to the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-184167-S30999457252005082200000) .
13. Install the inlet hose to the radiator.
14. Reposition the inlet hose clamp to the radiator.
15. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Remove the radiator. Refer to «Radiator Replacement (EXC 8.1L)»(ref-184167-S03807688442005082200000) or «Radiator Replacement (8.1L)»(ref-184167-S41016624552005082200000) .
2. Remove the radiator air baffle retainers.
3. Remove the radiator air baffles.

1. Install the radiator air baffles.
2. Install the radiator air baffle retainers.
3. Install the radiator. Refer to «Radiator Replacement (EXC 8.1L)»(ref-184167-S03807688442005082200000) or «Radiator Replacement (8.1L)»(ref-184167-S41016624552005082200000) .

1. Remove the radiator air upper baffle retainers.
2. Remove the radiator air upper baffle.

1. Install the radiator air upper baffle.
2. Install the radiator air upper baffle retainers.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Disconnect the heater cord from the coolant heater (4).
3. Loosen the coolant heater bolt.
4. Remove the coolant heater from the engine block.
5. Do not score the machined surface of the hole.
6. Grasp the plug with pliers.
7. Pull the plug from the engine block.
8. Clean the core plug hole in order to remove the following substances: Burrs Compound Paint Rough spots

1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 9985164 (Canadian P/N 10953480), or the equivalent.
2. Tightly push the coolant heater (1) into the engine block.
3. Tighten the coolant heater bolt until both of the locking wings draw tightly against the inner wall of the engine block. Tighten: Tighten the bolt to 2 N.m (18 lb in).
4. Connect the heater cord to the coolant heater (4).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
6. Inspect the cooling system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
3. Disconnect the coolant heater electrical connector (2).
4. Remove the coolant heater from the engine block.
5. Remove any burrs, sealer, paint or other rough spots.

1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads.
2. Install the coolant heater to the engine block. Tighten: Tighten the coolant heater to 50 N.m (37 lb ft).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-184215-S06199612502005082200000) in Tires and Wheels.
3. Remove the right engine mount. Refer to «Engine Mount Replacement - Right»(ref-184191-S27276107042005082200000) in Engine Mechanical - 6.6L (LB7), or «Engine Mount Replacement - Right»(ref-184188-S21886966202005082200000) in Engine Mechanical - 6.6L (LLY).
4. Disconnect the engine coolant heater cord.
5. Loosen the coolant heater bolt.
6. Remove the engine coolant heater from the engine block.
7. Do not score the machined surface of the hole.
8. Grasp the plug with pliers.
9. Pull the plug from the engine block.
10. Clean the core plug hole in order to remove the following substances: Burrs Compound Paint Rough spots

1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 1052196 (Canadian P/N 5264008), or the equivalent.
2. Align the coolant heater element to point towards the top of the engine.
3. Tightly push the coolant heater into the engine block.
4. Tighten the bolt on the engine coolant heater until both of the locking wings draw tightly against the inner wall of the engine block. Tighten: Tighten the bolt to 2 N.m (18 lb in).
5. Connect the heater cord to the coolant heater.
6. Remove the right engine mount. Refer to «Engine Mount Replacement - Right»(ref-184191-S27276107042005082200000) in Engine Mechanical - 6.6L (LB7), or «Engine Mount Replacement - Right»(ref-184188-S21886966202005082200000) in Engine Mechanical - 6.6L (LLY).
7. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-184215-S06199612502005082200000) in Tires and Wheels.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
9. Inspect for coolant leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Disconnect the block heater cord from the block heater.
3. Remove the engine block heater.

1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the engine block heater. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the engine block heater into the block. Tighten: Tighten the coolant heater to 60 N.m (40 lb ft).
3. Connect the block heater cord to the block heater.
4. Fill the cooling system. Refer to «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Disconnect the coolant heater electrical connector (2).
3. Remove the coolant heater cord retainer and bolts.
4. Remove the coolant heater cord.

Note. The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.

1. Install the coolant heater cord. NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the coolant heater cord bolts and retainer. Tighten: Tighten the bolts to 8 N.m (71 lb in).
3. Connect the coolant heater electrical connector (2).
4. Lower the vehicle.