Thermal Bypass Fitting Replacement (5.3L Engine W/RPO HP2)

Thermal Bypass Fitting Replacement (5.3L Engine w/RPO HP2)

Removal Procedure





1. Raise and suitably support the vehicle.
2. Drain the cooling system and engine block.
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.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.

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





1. Install the thermal bypass fitting.
Tighten the fitting to 35 Nm (26 ft. lbs.).





2. Install the thermal bypass hose to the fitting.
3. Position the thermal bypass hose clamp.
4. Install the thermal bypass hose bolt.
Tighten the bolt to 10 Nm (89 inch lbs.).





5. If necessary, connect the CKP sensor electrical connector.
6. Fill the cooling system and engine block.
7. Lower the vehicle.