Thermostat Housing Crossover Replacement Diesel

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the coolant from the radiator. Refer to Cooling System Draining and Filling .



3. Remove the air cleaner.
4. Remove the air cleaner resonator and the bracket.
5. Remove the bypass hose.
6. Remove the radiator inlet hose, or the upper hose.
7. Remove the heater hose.
8. Remove the bolts or the studs. Remove the gaskets.
9. Remove the crossover. The thermostat and the water outlet are attached to the crossover.
10. Inspect the crossover sealing surfaces. Ensure that the surfaces are clean.

1. Install the new gaskets into position.
2. Install the crossover.

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.

3. Install the bolts or the studs.

Tighten
Tighten the bolts or the studs to 47 N·m (35 lb ft).

4. Install the heater hose.
5. Install the radiator inlet hose.
6. Install the bypass hose.
7. Install the air cleaner resonator and the bracket.
8. Install the air cleaner.
9. Fill the cooling system. Refer to Cooling System Draining and Filling .
10. Start the engine. Run the engine with the radiator cap removed until the upper hose is hot and the thermostat is open.
11. While the engine is idling, add coolant to the surge tank until the coolant level reaches the bottom of the filler neck.
12. Attach the radiator cap to the surge tank. Ensure that the arrows line up with the overflow tube.
13. Connect the negative battery cable.