Thermostat Housing: Service and Repair

Thermostat Housing Crossover Replacement
Removal Procedure
1. Remove the air cleaner.
2. Remove the upper radiator fan shroud.
3. Remove the radiator fan.
4. Remove the engine cover.





5. Remove the main engine electrical harness connector hold down bolts.





6. Remove the main engine electrical harness connectors.
7. Disconnect and remove the barometric sensor.





8. Disconnect and remove the turbocharger vane position sensor.





9. Remove the main electrical harness bracket bolts.
10. Remove the main electrical harness bracket.





11. Disconnect the turbocharger coolant inlet hose.





12. Remove the electrical harness bracket bolt.
13. Remove the electrical harness bracket.





14. Remove the water outlet bolts.





15. Remove the water outlet.





16. Remove the oil fill tube bolts.





17. Remove the oil fill tube.





18. Disconnect the coolant temperature sensor.





19. Remove the EGR coolant pipe bolts.
20. Remove the EGR coolant pipe.





21. Remove the water pump inlet pipe bolts.





22. Remove the turbocharger coolant outlet hose and clamps.





23. Remove the water pump inlet pipe.





24. Remove the fuel pipe bracket bolt.





25. Remove the thermostat housing bolts.
26. Remove the thermostat housing.

Installation Procedure





1. Install the thermostat housing.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the thermostat housing bolts and nuts.
Tighten the thermostat housing bolts and nuts to 25 Nm (18 ft. lbs.).





3. Install the fuel pipe bracket bolt.
Tighten the fuel pipe bracket bolt to 25 Nm (18 ft. lbs.).





4. Install the water pump inlet pipe.





5. Install the turbocharger coolant outlet hose and clamps.





6. Install the water pump inlet pipe bolts.
Tighten the water pump inlet pipe bolts to 25 Nm (18 ft. lbs.).





7. Install the EGR coolant pipe.
8. Install the EGR coolant pipe bolts.
Tighten the EGR coolant pipe bolts to 25 Nm (18 ft. lbs.).





9. Connect the coolant temperature sensor.





10. Install the oil fill tube.





11. Install the oil fill tube bolts.
Tighten the oil fill tube bolts to 25 Nm (18 ft. lbs.).





12. Install the water outlet.





13. Install the water outlet bolts.
Tighten the water outlet bolts to 25 Nm (18 ft. lbs.).





14. Install the electrical harness bracket.
15. Install the electrical harness bracket bolt.
Tighten the electrical harness bracket bolt to 10 Nm (89 inch lbs.).





16. Connect the turbocharger coolant inlet hose.





17. Install the main electrical harness bracket.
18. Install the main electrical harness bracket bolts.
Tighten the main electrical harness bracket bolts to 10 Nm (89 inch lbs.).





19. Connect and install the turbocharger vane position sensor.





20. Connect and install the barometric sensor.





21. Install the main engine electrical harness connector hold down bolts.
Tighten the main electrical harness connector hold down bolts to 10 Nm (89 inch lbs.).
22. Install the radiator fan.
23. Install the upper radiator fan shroud.
24. Install the air cleaner.
25. Install the engine cover.