Thermostat Housing Crossover Replacement

REMOVAL PROCEDURE





1. Drain the engine coolant.
2. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair.
3. Remove the upper filler panel.
4. Remove the air cleaner assembly.
5. Remove the throttle body.
6. Remove the EGR pipe at the throttle body spacer.





7. Disconnect the upper radiator hose from housing.





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





9. Remove the water pump belt cover (1).





10. Remove the water pump belt tensioner (1).
11. Remove the water pump belt.
12. Remove the throttle body spacer.
13. Remove the EGR.
14. Disconnect the EGR pipe from the water crossover.
15. Disconnect the park neutral switch.





16. Remove the water pump cover.





17. 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 (18 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.
6. Install the throttle body spacer.





7. Install the water pump belt.
8. Install the water pump belt tensioner (1).





9. Install the water pump belt cover (1).





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.
14. Install the air cleaner assembly.
15. Install the upper filler panel.
16. Install the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair.
17. Refill the engine cooling system.