Coolant manifold (4.3L V6, 5.3L and 6.2L V8 models) — removal and installation
Warning: Wait until the engine is completely cool before beginning this procedure.
Removal
1. Disconnect the cable from the negative terminal of the battery (see Engine electrical systems).
2. Drain the coolant (see Tune-up and routine maintenance). Remove the air intake duct and resonator assembly (see Fuel and exhaust systems).
3. Remove the drivebelt (see Tune-up and routine maintenance).
4. Disconnect the electrical connector to the coolant temperature sensor (see Emissions and engine control systems).
5. Remove the alternator and alternator bracket (see Engine electrical systems).
6. Disconnect the expansion tank and radiator hoses from the thermostat housing (see illustration 4.4).
7. Disconnect the heater hoses from the coolant manifold (see illustration).
8.7 Use pliers to squeeze the spring clamps opern, then disconnect the hoses
8. Remove the coolant manifold bolts (see illustrations), then remove manifold and gaskets. It may be necessary to tap the housing with a soft-face hammer to break the gasket’s seal.
8.8a Remove the bracket mounting bolt from the side of coolant manifold
8.8b Coolant manifold bolt locations
Note: It is not necessary to remove the water pump from the coolant manifold to remove the coolant manifold.
Installation
9. Remove all traces of the old gaskets from the mounting surface on the engine. Do the same on the coolant manifold.
10. Clean the mounting bolt threads and threaded holes on the mounting surface to remove corrosion and sealant, then apply thread locking sealant to the bolt threads.
11. Place the gaskets and coolant manifold into position. Use caution to ensure that the gaskets don’t slip out of position. Install the mounting bolts until they are all finger-tight.
12. Tighten the bolts to the torque listed in this Chapter’s Specifications.
13. The remainder of installation is the reverse of the removal procedure.
14. Refill the engine with coolant (see Tune-up and routine maintenance). Run the engine and check for leak