GM Full-Size Trucks 1988-1998 Repair Information
Thermostat - REMOVAL & INSTALLATION
Diesel Engines
1988-95 models
Fig. 9: Thermostat housing-6.2L engines, R/V series
Fig. 10: Thermostat housing-6.2L and 6.5L diesel
engines-1988-95 C/K series
1996-98 Models
Fig. 11: Exploded view of the thermostat assembly
components-1996-98 diesel engines
To install:
continue...
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Thermostat Housing Crossover - REMOVAL & INSTALLATION
(This is found on the 6.2 and 6.5L diesel engines only)
CAUTION
Never open, service or drain the radiator or cooling system when
hot; serious burns can occur from the steam and hot coolant. Also, when
draining engine coolant, keep in mind that cats and dogs are attracted
to ethylene glycol antifreeze and could drink any that is left in an
uncovered container or in puddles on the ground. This will prove fatal
in sufficient quantities. Always drain coolant into a sealable
container. Coolant should be reused unless it is contaminated or is
several years old.
Drain the cooling system.
Remove the engine cover.
Remove the air cleaner and CDR valve.
Fig. 1: Thermostat housing crossover-1988-91 R/V series
Fig. 2: Thermostat housing crossover-1988-96 C/K series
Fig. 3: Thermostat housing crossover-1997-98 C/K series
Remove the air cleaner resonator and bracket.
Remove the upper fan shroud.
Remove the upper alternator bracket.
Remove the bypass hose.
Remove the upper radiator hose.
Disconnect the heater hose.
Remove the attaching bolts and lift out the crossover.
To install:
Thoroughly clean the mating surfaces.
Position the crossover, using new gaskets coated with sealer.
Install the attaching bolts and tighten them to 35 ft. lbs. (47
Nm) on 1988-91 engines, or 31 ft. lbs. (42 Nm) on 1992-98 engines.
Connect the heater hose.
Install the upper radiator hose.
Install the bypass hose.
Install the upper alternator bracket.
Install the upper fan shroud.
Install the air cleaner resonator and bracket.
Install the air cleaner and the CDR valve.
Install the engine cover.
Fill the cooling system.
Hope help with this.
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Hello, my name is Ben. I understand your frustration with this 4 bolt housing. After you remove the upper radiator hose, take a long extension and work from the rear of the engine. It's difficult but it can be done. And of course be very careful with re-installing those bolts so as to not cross thread them. Clean the gasket surfaces real good, obviously you do not want to go through this again. I hope this helps, good luck.
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Thanks Ben, but no way. That does not appear to be possible. Again, the question is, what do I have to remove to do this job. I do NOT want to start tearing stuff off the motor on a hit or miss basis. Can I do this job by removing the Turbo cover? Or the turbo cover and other stuff?
I'll take it, but be aware that the bottom driver side bolt can only be accessed easily if you remove the A/C compressor. Otherwise, you need to come in with a flex socket from the rear. In my case, it cannot be done because the bolt has been in place for 250,000 miles. Breaker bar doesn't work on an angle with a flex socket, or at least let's say I am not going to destroy a flex socket in the attempt. no more GM products for me, EVER.
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