For 1990-2009 cars

## Engine Coolant Thermostat Replacement 5.7L VIN P

### Removal Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Open the radiator drain cock. Drain the engine coolant from the radiator to a level below the thermostat.
2. Close the radiator drain cock.

Tighten
Tighten the drain cock to 1.5 N·m (13 lb in).

3. Remove the air intake duct and air cleaner.
4. Disconnect the outlet hose and clamp from the water outlet.
5. Remove the coolant water bolts (1) and the water outlet (2).

Remove the thermostat (4) and the gasket (3).

6. Thoroughly clean the gasket surfaces of the water outlet and the water pump.

### Installation Procedure

1. Install the thermostat (4) and a new gasket (3) with the taper up.
2. Install the water outlet (2) with the bolts (1) to the water pump.

Tighten
The water outlet bolts to 28 N·m (21 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Connect the outlet hose and clamp to the water outlet.
4. Install the air cleaner and the air intake duct.
5. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling .
6. START the engine. After the engine reaches normal operating temperature, check for coolant leaks.

## Engine Coolant Thermostat Replacement 3800 VIN K

### Removal Procedure

Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Open the radiator drain cock. Drain the engine coolant from the radiator to a level below the thermostat. Refer to Cooling System Draining and Filling .
2. Close the radiator drain cock.

Tighten
Tighten the radiator drain cock to 1.5 N·m (13 lb in).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Remove the EGR valve outlet pipe screw from the upper intake and the nut from the EGR valve adapter.
4. Remove the EGR valve outlet pipe.
5. Remove the clamp (3) and the inlet hose (4) from the water outlet.
6. Remove the water outlet bolts (1).
7. Remove the water outlet (2).
8. Remove the water outlet gasket (6).
9. Remove the engine coolant thermostat (5).
10. Clean the gasket surfaces of the water outlet and upper intake manifold.

### Installation Procedure

1. Install the engine coolant thermostat (5) and a new gasket (6) into the upper intake manifold.
2. Install the water outlet (2).
3. Install the water outlet bolts (1).

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

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the inlet hose (4) and the clamp (3) to the water outlet.
5. Install the EGR valve outlet pipe.

Install the EGR valve outlet pipe screw to the upper intake manifold and the nut to the EGR valve adapter.

Tighten

• | Tighten the EGR valve outlet pipe screw to the upper intake manifold to 25 N·m (18 lb ft).

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

6. START the engine. After the engine reaches normal operating temperature, check for coolant leaks.