Engine Coolant Crossover Pipe Replacement 8.1L Engine

1. Remove the air cleaner layer. Refer to Air Cleaner Replacement for the 8.1L engine.
2. Drain the cooling system. Refer to Cooling System Draining and Filling.



3. Remove the inlet hose from the water crossover.
4. Reposition the inlet hose clamp at the water crossover.
5. Remove the drive belt. Refer to Drive Belt Replacement for the 8.1L engine.
6. Remove the generator and generator bracket. Refer to Generator Replacement and to Generator Bracket Replacement.
7. If equipped with regular production option (RPO) KZX, remove the air compressor and air compressor bracket. Refer to Air Compressor Replacement and Air Compressor Bracket Replacement - Front.
8. Remove the power steering pump bracket. Refer to Power Steering Pump Replacement.



9. Remove the heater inlet hose from the water crossover.
10. Reposition the heater inlet hose clamp at the water crossover.



11. Remove the bypass hose.
12. Reposition the bypass hose clamps at the water crossover and water pump.



13. Remove the water crossover bolts.
14. Remove the water crossover.
15. Remove and discard the water crossover gaskets.



16. If replacing the water crossover remove the following:

16.1.

Water outlet bolts (2)

16.2.

Water outlet (1)

16.3.

Thermostat (3)

Caution: Refer to Fastener Caution in the Preface section.




1. If replacing the water crossover install the following:

1.1.	Thermostat (3)

1.2.	Water outlet (1)

1.3.	Water outlet bolts (2)

Tighten
Tighten the bolts to 30 N·m (22 lb ft).




2. Install NEW water crossover gaskets.
3. Install the water crossover.
4. Install the water crossover bolts.

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




5. Install the bypass hose.
6. Position the bypass hose clamps at the water crossover and water pump.



7. Install the heater inlet hose to the water crossover.
8. Position the heater inlet hose clamp at the water crossover.



9. Install the inlet hose to the water crossover.
10. Position the inlet hose clamp at the water crossover.
11. Install the power steering pump bracket and power steering pump. Refer to Power Steering Pump Replacement.
12. Install the generator bracket and the generator. Refer to Generator Bracket Replacement and to Generator Replacement.
13. If equipped with RPO KZX, install the air compressor bracket and the air compressor. Refer to Air Compressor Replacement and Air Compressor Bracket Replacement - Front.
14. Install the drive belt. Refer to Drive Belt Replacement for the 8.1L engine.
15. Install the air cleaner layer. Refer to Air Cleaner Replacement for the 8.1L engine.
16. Fill the cooling system. Refer to Cooling System Draining and Filling.