Water Crossover Installation C/K

1. Install the thermostat (3) with the seal into the coolant crossover (7).
2. Install the water outlet (1).

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 water outlet bolts (2).

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




4. Place the coolant crossover gaskets and the coolant crossover in position.
5. Install the coolant crossover bolts.

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




6. Install the thermostat bypass hose clamps onto the thermostat bypass hose.
7. Install the thermostat bypass hose.

Important: Properly position the bypass hose clamps to avoid water pump pulley interference.

8. Position the thermostat bypass hose clamps.



9. Install the drive belt tensioner.
10. Install the drive belt tensioner bolts.

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

Water Crossover Installation Medium Duty

1. Install the thermostat (6) with the seal into the coolant crossover.
2. Install the water outlet (1).

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 water outlet bolts (7).

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




4. Place the coolant crossover gaskets and the coolant crossover in position.
5. Install the coolant crossover bolts.

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




6. Install the thermostat bypass hose clamps onto the thermostat bypass hose.
7. Install the thermostat bypass hose.

Important: Properly position the bypass hose clamps to avoid water pump pulley interference.

8. Position the thermostat bypass hose clamps.

Water Crossover Installation G/C3500HD

1. Install the thermostat (3) with the seal into the coolant crossover (7).
2. Install the water outlet (1).

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 water outlet bolts (2).

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




4. Place the coolant crossover gaskets and the coolant crossover in position.
5. Install the coolant crossover bolts.

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




6. Install the thermostat bypass hose clamps onto the thermostat bypass hose.
7. Install the thermostat bypass hose.

Important: Properly position the bypass hose clamps to avoid water pump pulley interference.

8. Position the thermostat bypass hose clamps.