Coolant Line/Hose: Service and Repair

WATER CROSSOVER REPLACEMENT

TOOLS REQUIRED
- J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. Drain the cooling system.
2. Remove the air cleaner assembly.
3. Remove the fuel injector sight shield.






4. Disconnect the brake booster vacuum tube from the water housing crossover.
5. Disconnect the fuel regulator vacuum tube (1).
6. Disconnect the AIR solenoid vacuum tube (2).
7. Remove the throttle body.






8. Disconnect the fuel rail bracket retaining nut at the rear lift bracket.
9. Disconnect the surge tank inlet hose from the fitting.






10. Remove the surge tank inlet fitting.
11. Remove the rear lift bracket bolt.
12. Remove the rear lift bracket.
13. Remove the EGR valve.






14. Disconnect the EGR inlet pipe nut (1) from the exhaust crossover.

IMPORTANT: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

15. Remove the EGR inlet pipe bolt (2) and flange (3) from the water crossover.
16. Remove the EGR inlet pipe and discard.
17. Remove the EVAP emission canister purge valve.






18. Disconnect the electrical connector from the MAP sensor.
19. Remove the MAP sensor.






20. Position the J 38185 (2) to the clamp in order to remove the inlet radiator hose (1) from the water housing crossover.






21. Position the J 38185 to the clamp in order to remove the outlet radiator hose (2) from the thermostat housing.
22. Remove the water pump.






23. Remove the 2 bolts (3) attaching the water pump belt tensioner (1) to the water crossover.
24. Remove the water pump belt tensioner (1).






25. Disconnect the cable harness clip at the water housing crossover and position aside.
26. Disconnect the heater hose from the water housing crossover.
27. Remove the water housing crossover from the engine.
28. Clean and inspect the water housing crossover.

INSTALLATION PROCEDURE






1. With all 8 crossover retaining bolts inserted, slide the upper and lower water housing crossover gaskets onto the bolts.

IMPORTANT: Care should be taken when installing the water housing bolts, so that the gaskets are in the correct position.

2. Place the water housing crossover in position and hand start the bolts 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.






3. Tighten the water housing crossover bolts.

TIGHTEN
- Water housing crossover bolts to 25 Nm (18 lb ft).

4. Connect the heater hose to the water housing crossover.
5. Connect the cable harness clip to the water housing crossover.






6. Install the 2 bolts (3) attaching the water pump belt tensioner (1) to the water crossover.

TIGHTEN
- Tighten the water pump belt tensioner bolts to 10 Nm (89 lb in).

7. Install the water pump.






8. Position the J 38185 to the clamp in order to connect the outlet radiator hose (2) to the thermostat housing.






9. Position the J 38185 (2) to the clamp in order to connect the inlet radiator hose (1) to the water housing crossover.






10. Install the MAP sensor.
11. Connect the electrical connector to the MAP sensor.
12. Install the EGR valve.






IMPORTANT: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

13. Hand start the NEW EGR inlet pipe-to-crossover pipe nut (1) to prevent cross threading.

TIGHTEN
- EGR inlet pipe nut to 60 Nm (44 lb ft).

14. Connect the EGR inlet pipe flange (3) to the water crossover.
15. Install the EGR inlet pipe-to-water crossover flange bolt (2).

TIGHTEN
- Tighten the EGR inlet pipe bolt to 25 Nm (18 lb ft).

16. Install the EVAP emission canister purge valve.






17. Position the rear lift bracket to the water crossover.
18. Install the rear lift bracket bolt.

TIGHTEN
- Rear lift bracket bolt to 24 Nm (18 lb ft).

19. Install the surge tank inlet fitting.

TIGHTEN
- Tighten the surge tank inlet fitting to 47 Nm (35 lb ft).






20. Connect the surge tank inlet hose to the fitting.
21. Connect the fuel rail bracket retaining nut to the rear lift bracket.

TIGHTEN
- Fuel rail bracket retaining nut to 4 Nm (35 lb in).






22. Connect the AIR solenoid vacuum tube (2) to the housing crossover.
23. Connect the fuel regulator vacuum tube (1).
24. Connect the brake booster vacuum tube.
25. Install the throttle body.
26. Install the fuel injector sight shield.
27. Install the air cleaner assembly.
28. Fill the cooling system.