Thermostat Housing Crossover Replacement

REMOVAL PROCEDURE





1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
2. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair.
3. Remove the upper filler panel. Refer to Upper Filler Panel in Body.
4. Remove the air cleaner assembly. Refer to Air Cleaner in Powertrain Management.
5. Disconnect the shift selector cable.
6. Remove the throttle cable bracket
7. Remove the throttle body. Refer to Throttle Body in Powertrain Management.
8. Remove the EGR pipe at the throttle body spacer.





9. Disconnect the upper radiator hose from housing.





10. Disconnect the lower radiator hose from the thermostat housing.





11. Remove the water pump belt cover.
12. Remove the water pump belt tensioner.
13. Remove the water pump belt.
14. Remove the throttle body spacer. Refer to Throttle Body in Powertrain Management.
15. Remove the EGR. Refer to EGR in Powertrain Management.
16. Disconnect the EGR pipe from the water crossover.
17. Disconnect the park neutral switch.





18. Remove the water pump cover.





19. Remove the water crossover from the engine.

INSTALLATION PROCEDURE





1. Install the water crossover on the engine.
^ Tighten the water crossover bolts to 25 Nm (118 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





2. Install the water pump cover.
^ Tighten the water pump cover to 10 Nm (89 inch lbs.).

3. Connect the park neutral switch.
4. Connect the EGR pipe to the water crossover.
5. Install the EGR. Refer to EGR in Powertrain Management.
6. Install the throttle body spacer. Refer to Throttle Body in Powertrain Management.





7. Install the water pump belt. Refer to Water Pump Belt in Cooling System.
8. Install the water pump belt tensioner. Refer to Cooling System.
9. Install the Water pump belt cover.





10. Connect the lower radiator hose to the thermostat housing.





11. Connect the upper radiator hose to the housing.
12. Install the EGR pipe to the throttle body spacer.





13. Install the throttle body. Refer to Throttle Body in Powertrain Management.
14. Install the throttle cable bracket.
15. Connect the shift selector cable.
16. Install the air cleaner assembly. Refer to Air Cleaner in Powertrain Management.
17. Install the upper filler panel. Refer to Upper Filler Panel in Body and Frame.
18. Install the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair.
19. Refill the Cooling System system. Refer to Draining and Filling Cooling System in Cooling System.