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SECTION 2: POWERSTAT INSTALLATION
For 1999-2003 4.8/5.3/6.0L GM vehicles
Tools needed:
10mm socket, ratchet, and extension
Slip joint pliers
DEX-COOL anti-freeze coolant
NOTE: The thermostat in this engine is a “housing” style
thermostat. It is located on the front of the water pump
assembly at the bottom edge of the passenger side
cylinder head. (See Figure C)
Part #1015 - 180° PowerStat (1999-2003 ONLY)
1. Make sure that the vehicle is parked on a level surface before
installing the Hypertech PowerStat.
2. Allow the vehicle coolant to cool.
3. Turn the surge tank cap counter-clockwise very slowly to
remove the pressure from the cooling system. If you hear a
hissing or spurting sound, stop and let the pressure bleed off.
When the hissing or spurting sound goes away, finish
removing the surge tank cap.
4. Open the radiator drain plug and drain the coolant from the
vehicle.
5. Remove the radiator hose from the stock thermostat.
6. Remove the two (2) 10mm bolts holding the stock thermostat
to the engine. (You may want to use an extension on the
socket wrench for easier access.)
7. Lift out the stock thermostat. Use a flathead screwdriver to
gently pry, if necessary. Clean all the sealing surfaces.
8. Install the Hypertech PowerStat, making sure the O Ring is
sealed properly. For ease of installation, you may want to
apply a small amount of grease to the PowerStat to help
retain the O Ring.
NOTE: After installing
the PowerStat, if any
coolant needs to be
added to the vehicle,
make sure you
put the same color
coolant back into the
vehicle. If your vehicle
has orange coolant,
replace with orange
coolant. If green,
replace with green.
To complete your performance package, you may choose to use
a low-temp thermostat. Replacing the factory thermostat with a
Hypertech PowerStat will allow the engine to run cooler, increasing
power, and reducing the engine’s tendency to detonate.
• For 4.3 & 8.1L vehicles, Hypertech recommends using
the stock
thermostat. For 1999-2003 4.8/5.3/6.0L vehicles,
Hypertech recommends
using the 180° PowerStat. The
PowerStat is NOT available for 2004-2005 GM trucks/SUVs.
• WARNING: Never attempt to change a
thermostat on a hot engine.
• Serious injury can occur if the radiator cap
is removed while the cooling system is hot.
• The engine should always be cold when
installing the Powerstat.
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