Engine Coolant Crossover Pipe Replacement 8.1L Engine

1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory in Engine Mechanical - 8.1 L.
3. Position the inlet hose clamp at the water crossover.
4. Remove the inlet hose from the water crossover.



5. Position the heater inlet hose clamp at the water crossover.
6. Remove the heater inlet hose from the water crossover.



7. Position the bypass hose clamps at the water crossover and water pump.
8. Remove the bypass hose.



9. Remove the generator. Refer to Generator Replacement in Engine Electrical.
10. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
11. Remove the generator bracket bolts and nut.
12. Remove the generator bracket stud.
13. Remove the generator bracket.



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



17. If replacing the water crossover remove the following:

17.1.

Water outlet bolts (2)

17.2.

Water outlet (1)

17.3.

Thermostat (3)

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.

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 generator bracket.
6. Install the generator bracket stud.

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

7. Install the generator bracket bolts and nut.

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

8. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
9. Install the generator. Refer to Generator Replacement in Engine Electrical.



10. Install the bypass hose.
11. Position the bypass hose clamps at the water crossover and water pump.



12. Install the heater inlet hose to the water crossover.
13. Position the heater inlet hose clamp at the water crossover.



14. Install the inlet hose to the water crossover.
15. Position the inlet hose clamp at the water crossover.
16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory in Engine Mechanical - 8.1 L.
17. Fill the cooling system. Refer to Cooling System Draining and Filling .