Engine Coolant Crossover Pipe Replacement 8.1L Engine

Important: The water crossover can be removed as an assembly if not replacing individual components.

1. Disconnect the mass airflow (MAF) sensor electrical connector (4).
2. Disengage the cover clips (2).
3. Remove the air cleaner cover (1).



4. Loosen the air intake duct clamp at the throttle body.
5. Remove the air intake duct and air cleaner element.
6. Drain the cooling system. Refer to Cooling System Draining and Filling .



7. Reposition the heater inlet hose clamp (2).
8. Remove the heater inlet hose (1) from the hose connector (3).



9. Remove the air conditioning (A/C) compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation, and Air Conditioning.
10. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
11. Remove the power steering pump bracket bolts and nut.
12. Remove the power steering pump stud.



13. Remove the generator bracket. Refer to Generator Bracket Replacement in Engine Electrical.
14. Reposition the bypass hose clamps at the crossover and water pump.
15. Remove the bypass hose.



16. Reposition the inlet hose clamp (1) at the water crossover.
17. Remove the inlet hose (2) from the water crossover.



18. Remove the water crossover bolts.
19. Remove the water crossover.
20. Remove the water crossover gaskets.
21. Clean and inspect the water crossover. Refer to Water Crossover Cleaning and Inspection in Engine Mechanical - 8.1L - Unit Repair.

1. Place the water crossover gaskets and crossover into place.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the water crossover bolts.

Tighten
Tighten the water crossover bolts to 50 N·m (37 lb ft).




3. Install the inlet hose (2) to the water crossover.
4. Position the inlet hose clamp (1) at the water crossover.



5. Install the bypass hose.
6. Position the bypass hose clamps at the crossover and water pump.
7. Install the generator bracket. Refer to Generator Bracket Replacement in Engine Electrical.



8. Install the power steering pump stud.

Tighten
Tighten the power steering pump stud to 20 N·m (15 lb ft).

9. Install the power steering pump bracket bolts and nut.

Tighten
Tighten the power steering pump bracket bolts/nut to 50 N·m (37 lb ft).

10. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
11. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation, and Air Conditioning.



12. Install the heater inlet hose (1) to the hose connector (3).
13. Position the heater inlet hose clamp (2).
14. Fill the cooling system. Refer to Cooling System Draining and Filling .



15. Install the air intake duct and air cleaner element.
16. Tighten the air intake duct clamp at the throttle body.

Tighten
Tighten the air intake duct clamp to 3 N·m (26 lb in).




17. Install the air cleaner cover (1).
18. Engage the cover clips (2).
19. Connect the MAF sensor electrical connector (4).