Begin the thermostat housing service and repair by draining part of the coolant from the radiator into a container, making sure you do not discard unused coolant. For constant tension hose clamps use the special clamp tool (number 6094) and the Snap-On clamp tool (number HPC-20) when the clamps are large and ensure you are wearing safety glasses. When you must use a new constant tension clamp, be sure it is identical to the one that was used before and has the same letter or number that originally appeared on it. If your vehicle lacks air conditioning, get rid of both bypass hose clamps, set the hose in the center and free the hose. When the vehicle has air conditioning, separate the negative terminal from the battery, partially drain the cooling system, unclip the upper radiator hose clamp, remove the hose plus wiring connector from the A/C compressor, take off the air cleaner assembly and lastly remove the accessory
Drive Belt. One of the A/C compressor/generator bracket mounting bolts can only be accessed after the drive belt idler pulley is removed. Once you take out the oil dipstick tube mounting bolt, unhook the throttle body cables, remove the hose clamp and hose and then remove the heater hose coolant return tube, discarding its old O-ring. After that, get rid of the bypass hose support plate using the highlighted hex wrench, take out the bracket-to-intake manifold bolts and six bracket bolts and lift the generator and A/C compressor assembly up to expose the bypass hose-use a block of wood to keep the supported assembly off the ground. Place and adjust both clamps over the center area of the bypass hose and then remove it. For installation, put the bypass hose clamps at the hose's center point, install the bypass hose onto the engine and secure both the clamps. Refill the cooling system, start the engine and see if it is leaking. Once you have installed the bypass hose on a vehicle with air conditioning, add the generator-A/C mounting bracket assembly in position and tighten bolts (number 1 and 2) to 54 Nm (40 ft. lbs.); tighten the third bolt to 40 Nm (30 ft. lbs.). Put on a different O-ring to the heater hose coolant return tube, coat it with antifreeze and then attach the tube and its securing bolt to the engine. Rearrange the control wiring for the throttle body, set the oil dipstick mounting bolt and the idler pulley and tighten both fasteners to 54 Nm (40 ft. lbs.). Hold on to the drive belt while you insert it so it doesn't slip, then add the air cleaner assembly, connect the top radiator hose to the radiator, plug the wiring into the A/C compressor and finally reconnect the battery negative wire. After that, complete filling the coolant, ignite the engine, let it warm up and check for flow leaks.