Engine Coolant Crossover Pipe Replacement 3.5L (L66)

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the battery. Refer to Battery Replacement .
3. Drain the engine coolant. Refer to Cooling System Draining and Filling .
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector .
5. Remove the ECT sensor.
6. Remove the radiator inlet and outlet hoses from the crossover pipe.
7. Disconnect the wiring harness ground terminal from the crossover pipe.



8. Remove the thermostat housing and thermostat from the crossover pipe.



9. Remove the crossover pipe bolts and crossover pipe.

1. Clean and dry the area before installing new seals.
2. Install the crossover pipe.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the crossover pipe bolts.

Tighten
Tighten the crossover pipe bolts to 22 N·m (16 lb ft).

4. Install the thermostat and thermostat housing.

Tighten
Tighten the thermostat housing bolts to 12 N·m (106 lb in).

5. Connect the coolant hoses at the crossover pipe.
6. Connect the wiring harness ground terminal to the crossover pipe.

Tighten
Tighten the nut to 12 N·m (106 lb in).




7. Apply thread sealant (Saturn P/N 21485277) Loctite™ 242 threadlocker, or equivalent, to sensor threads.
8. Install the ECT sensor.

Tighten
Tighten the ECT sensor to 18 N·m (13 lb ft).

9. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
10. Install the battery. Refer to Battery Replacement .
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Tighten
Tighten the battery terminal bolt to 17 N·m (13 lb ft).

12. Fill the coolant. Refer to Cooling System Draining and Filling .