Engine Coolant Crossover Pipe Replacement RPO LZ9

Tools Required

J 38185 (SA9111E) Hose Clamp Pliers

1. Drain the cooling system. Refer to Cooling System Draining and Filling .



2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
3. Remove the generator. Refer to Generator Replacement .
4. Remove the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement .
5. Remove the power steering pump. Refer to Power Steering Pump Replacement .
6. Reposition the coolant recovery reservoir inlet hose clamp (1) at the coolant crossover.
7. Remove the coolant recovery reservoir inlet hose (2) from the coolant crossover.



8. Using the J 38185 release the tension on the hose clamp at the coolant crossover.
9. Remove the radiator inlet hose from the crossover pipe.



10. Reposition the thermal bypass hose clamp at the crossover pipe.
11. Remove the thermal bypass hose from the crossover pipe.
12. Remove the bolt holding the heater pipe and wiring harness at the coolant crossover pipe.
13. Remove the bolt holding the heater pipe on the left cylinder head.
14. Position aside the heater pipe.



15. Remove the coolant crossover pipe bolts (1-4).
16. Remove the coolant crossover pipe.

1. Position the coolant crossover pipe to the cylinder heads.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the coolant crossover pipe bolts (1-4).

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

3. Reposition the heater pipe.
4. Install the bolt holding the heater pipe to the left cylinder head.
5. Install the bolt holding the heater pipe and wiring harness to the coolant crossover pipe.



6. Install the thermal bypass hose to the crossover pipe.
7. Position the thermal bypass hose clamp at the crossover pipe.



8. Install the radiator inlet hose to the crossover pipe.
9. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the coolant crossover.



10. Install the coolant recovery reservoir inlet hose (2) to the coolant crossover.
11. Position the coolant recovery reservoir inlet hose clamp (1) at the coolant crossover.
12. Install the power steering pump. Refer to Power Steering Pump Replacement .
13. Install the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement .
14. Install the generator. Refer to Generator Replacement .
15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
16. Vac and fill the cooling system. Refer to Cooling System Draining and Filling .