Coolant Line/Hose: Service and Repair

WATER CROSSOVER REMOVAL






1. Remove the lift bracket retaining studs (2).
2. Remove the lift bracket (1) from the cylinder head.






3. Remove the coolant temperature sensor from the cylinder head.






4. Remove the EGR valve bolts.
5. Remove the EGR valve and the gasket.






6. Loosen the water crossover mounting bolts (1-5).






7. Remove the water crossover and all mounting bolts (1-3).






8. Remove the upper (1) and lower (2) water crossover gaskets. Do not damage the water crossover gaskets. These gaskets are reusable.


WATER CROSSOVER INSTALLATION






1. With the water crossover on the bench, install all eight crossover retaining bolts.
a. The longest bolts belong in the positions (1) and (4).
b. The medium length bolts belong in positions (2) and (3).
c. The single short bolt belongs in position (5).






2. Slide the upper (1) and lower (2) water crossover gaskets onto the bolts with the crossover still on the bench.






3. Place the water crossover in position and hand start the bolts identified (1-3) to hold the crossover in place.

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.






4. Hand start the remaining bolts.

TIGHTEN
- all water crossover bolts (1-5) to 25 Nm (18 lb ft).






5. Install a new EGR valve gasket on the EGR valve.
6. Install the EGR valve and the retaining bolts.

TIGHTEN
- EGR valve bolts to 24 Nm (18 lb ft).






7. Install the coolant temperature sensor in the cylinder head.

TIGHTEN
- Coolant temperature sensor to 20 Nm (15 lb ft).






8. Place the rear lift bracket (1) in position at the rear of the cylinder head.
9. Install the lift bracket retaining studs (2).

TIGHTEN
- Lift bracket retaining studs to 50 Nm 37 lb ft).