82. Water Crossover Assemble

Water Crossover Assemble

^ Tools Required
- J 38816-A Water Pump Remover/Installer

Notice: Refer to Fastener Notice in Service Precautions.





1. Install the water pump and seal using the following procedure:
1.1. Install the new water pump seal.
1.2. Place the water pump into the water crossover. Ensure the water pump tabs are correctly indexing the water crossover tabs.
1.3. Index the J 38816-A socket into the water pump.
1.4. Align the J 38816-A support plate on the water crossover.
1.5. Install the J 38816-A support plate on the water crossover using the water pump cover bolts.
1.6. Tighten the water pump in the water crossover by turning the J 38816-A socket counter-clockwise.
^ Tighten the J 38816-A socket to 100 Nm (74 ft. lbs.).
1.7. Remove the J 38816-A support plate from the water crossover.
1.8. Remove the J 38816-A socket.





2. Install the water pump cover gasket.
3. Install the water outlet and thermostat.
4. Install the water outlet bolts.
^ Tighten the water outlet bolts to 10 Nm (89 inch lbs.).





5. Install the water pump cover.





Important: Ensure the bolt is installed in the lower inboard position (1) and the studs are installed in the remaining positions (2).

6. Install the water pump cover bolt and studs.
^ Tighten the water pump cover bolt and studs to 10 Nm (89 inch lbs.).





7. Install the MAP sensor.





8. Install the accelerator control cable bracket.
9. Install the accelerator control cable bracket bolts.
^ Tighten the accelerator control cable bracket bolts to 9 Nm (80 inch lbs.).





Important: Do not use any type of sealant between the NEW plenum duct and the water crossover.

10. Install the throttle body and the NEW plenum duct.
11. Install the throttle body bolts.
^ Tighten the throttle body bolts to 10 Nm (89 inch lbs.).





12. Install the EGR gasket.
13. Install the EGR valve.
14. Install the EGR valve bolts.
^ Tighten the EGR valve bolts to 24 Nm (17 ft. lbs.).





15. Install the EGR bracket shield.
16. Install the EGR bracket shield nut.
^ Tighten the EGR bracket shield nut to 10 Nm (89 inch lbs.).





17. Install the EVAP emission canister purge valve.
18. Install the EVAP emission canister purge valve bolts.
^ Tighten the EVAP emission canister purge valve bolts to 10 Nm (89 inch lbs.).





19. Install the rear lift bracket.
20. Install the rear lift bracket bolt.
^ Tighten the rear lift bracket bolt to 24 Nm (17 ft. lbs.).
21. Install the engine coolant outlet fitting.
^ Tighten the engine coolant outlet fitting to 47 Nm (35 ft. lbs.).





22. Install the heater inlet pipe fitting.
^ Tighten the heater inlet pipe fitting to 40 Nm (30 ft. lbs.).