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Coolant loss through the water pump bearing seal is commonly caused by a faulty cooling system pressure cap. With certain designs of the plastic pressure cap, if the cooling system overheats distortion of the pressure relief valve in the cap can cause the valve to stick and result in excessive pressure in the cooling system. It is recommended that the coolant pressure cap is always checked for correct operation, prior to the fitment of a new water pump. Thermostat Testing In order to confirm if the thermostat is operating as required, the correct testing procedure should be adopted. Equipment required : 1) A container of undiluted anti-freeze mixture, to allow the temperature of the liquid to be raised above boiling point. (DO NOT use plain water). 2) A suitable heating element to raise the temperature of the liquid. 3) An accurately calibrated thermometer, with a range suitable for the thermostat to be tested. Testing Lower the thermostat into the container of anti-freeze, along with the thermometer, and heat the liquid slowly to the temperature marked on the thermostat, e.g 88 degrees, whilst agitating the thermostat. Let the temperature remain stable for one minute, then check for initial opening of the thermostat valve, Note: The valve will only just crack open at this temperature. Increase the temperature of the liquid to at least 14 degrees above the initial opening temperature, e.g.102 degrees, again allow one minute, then check the valve is fully opened. Allow the liquid to cool to below the initial opening temperature, then check that the valve is fully closed. Opening and fully open temperatures should be within plus or minus 2 degrees of those stated A build up of sediment coating on the thermostat can adversely effect the performance of the thermostat.

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Removal NOTE: Removal of the vertical EGR cooler is not required to service the thermostats. 1. Remove the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section. 2. Remove the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 3. Using a mirror, find the end of the upper radiator hose spring clip. Remove the spring clip, disconnect the upper radiator hose from the thermostat housing and position the upper radiator hose aside. 4. Remove and discard the nut and the vertical EGR cooler lower clamp. 5. Remove the bolt and the vertical EGR cooler lower bracket. 6. NOTE: Vertical EGR cooler removed from art for clarity. Disconnect the wiring from the heater return tube. 7. Remove the 2 bolts and position out the LH heater return tube. • Remove and discard the O-ring seal. 8. NOTE: The 6.4L diesel engine uses 2 thermostats. Remove the 4 bolts, the collar and the thermostat housing. • Lift the bottom of the collar up and rotate toward the engine to remove. 9. NOTICE: If the thermostats are contaminated with engine oil, new thermostats must be installed. Reusing a thermostat that has been exposed to engine oil may result in engine overheating. Remove the thermostats and the gasket from the thermostat housing. • Discard the gasket. Installation 1. Install a new gasket and the thermostats into the thermostat housing. 2. Install the thermostat housing, the collar and the 4 bolts. • Tighten to 13 Nm (115 lb-in). 3. NOTE: Vertical EGR cooler removed from art for clarity. NOTE: Install a new O-ring seal. Install the LH heater return tube and the 2 bolts. • Tighten to 13 Nm (115 lb-in). 4. Connect the wiring to the heater return tube. 5. Position the lower vertical EGR cooler bracket and loosely install the bolt. 6. Install a new vertical EGR cooler lower clamp. Tighten the clamp nut in 3 stages. • Stage 1: Tighten the nut to 10 Nm (89 lb-in). • Stage 2: Loosen the nut 720 degrees (2 complete turns). • Stage 3: Tighten the nut to 8 Nm (71 lb-in). 7. Tighten the lower EGR cooler bracket bolt. • Tighten to 62 Nm (46 lb-ft). 8. Connect the upper radiator hose to the thermostat housing. Install the spring clip. • Verify the spring clip is correctly seated. 9. Install the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 10. Install the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section.

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1. Drain the cooling system. Refer to the procedure in this section. 2. Remove the upper radiator hose bracket bolt and the upper radiator hose bracket. 3. Reposition the water bypass hose clamp and remove the water bypass hose (8597) from the water hose connection (8592) . 4. If equipped with A/C, remove the drier to evaporator liquid line bracket bolt and the drier to evaporator liquid line bracket to gain access to the water thermostat (8575) . 5. If equipped with A/C, remove the suction accumulator/drier bracket bolts and the suction accumulator/drier bracket. 6. If equipped with A/C, position the suction accumulator/drier (19C836) and drier to evaporator liquid line (19837) out of the way. 7. Remove the four water hose connection bolts and the water hose connection. 8. Remove the water thermostat from the thermostat housing. Installation 1. Clean the thermostat housing cover mating surface and groove of any remaining sealant. 2. Completely clean any coolant from these areas. 3. NOTE: Position the water hose connection on the thermostat housing within five minutes of applying the silicone sealant. Apply a continuous bead of silicone sealant to the inner surface and the perimeter of the water hose connection . The sealant should be 2.0-3.0mm (0.08-0.12 inch) wide on all sealing areas. 4. NOTE: When installing the water thermostat , ensure the jiggle valve is pointing upward.

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Except Air-Conditioned Cars 1967 MODELS 1. Disconnect the negative battery cable and drain the radiator. 2. Remove the heater hoses from the core. The top hose connects to the water pump and the lower hose goes to the thermostat housing or intake manifold. 3. Remove the cables and all electrical connections from the heater and defroster assembly. 4. Remove the nuts from the core case studs located on the firewall. 5. From inside the car, remove the case-to-firewall mounting screws and the heater and defroster assembly. 6. Remove the retaining springs and core. 7. Install the core and retaining springs, making sure the core-to-case sealer is in good condition. 8. Complete the installation by reversing the removal procedure. 1968-77 MODELS 1. Disconnect the negative battery cable. 2. Drain the radiator. 3. Disconnect the heater hoses. Plug the core inlet and outlet. 4. Remove the nuts from the air distributor duct studs on the firewall. 5. On 1970-77 Camaros: remove the glove box and radio, then the defroster duct-to-distributor duct screw. Pull the defroster duct out of the way, then pull the distributor duct from the firewall mounting. Remove the resistor wires. Lay the duct on the floor. 7. Remove the core assembly from the distributor duct. 8. Reverse the procedure to install. Use new sealer on the duct flange, if necessary.

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Some customers may comment on a check engine light being illuminated. This condition is intermittent and upon investigation, the technician may find DTC P0128 set. Correction Verify that the cooling system is filled to the proper level and using a scan tool, verify that the thermostat is opening at the proper temperature. If everything is functioning properly, then reprogram the PCM with a new calibration using the Service Programming System (SPS). An updated PCM calibration has been released to address this condition. This new service calibration is available on TIS2WEB. Important: The new calibration is included in a calibration that addresses long crank time in hot restart situations.