Thermostat Housing Crossover Replacement

Thermostat Housing Crossover Replacement

Removal Procedure

1. Remove the radiator fan. Refer to Fan Replacement (Fan Replacement).
2. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Radiator Inlet Hose Replacement)
3. Remove the fuel return canister from the clip retainer at the top of the thermostat housing.
4. Remove the drive belt tensioner. Refer to Drive Belt Replacement ().
5. Remove the generator bracket. Refer to Generator Bracket Replacement Generator Bracket Replacement
6. Remove the air conditioning (A/C) and power steering bracket.




7. Remove the fuel pressure valve bolt (1) and reposition the fuel line (2).




8. Disconnect the engine coolant temperature sensor electrical connector (1).
9. Remove the turbocharger coolant feed hose (2).
10. Remove the oil fill tube bolt (3); the oil fill tube retainer bracket bolt (4) and the oil fill tube (5).




11. Disconnect the turbocharger coolant return hose (1) at the thermostat bypass pipe (3).
12. Remove the thermostat bypass bolts (2) at the water pump and remove the thermostat bypass pipe (3).




13. Remove the thermostat housing crossover bolts (1) and nuts (2).
14. Remove the thermostat housing crossover pipe (4) and gaskets (3).

Installation Procedure

1. Position the thermostat housing crossover with NEW gaskets.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the thermostat housing crossover bolts (1) and nuts (2).Tighten to 25 Nm (18 lb ft).




3. Install the thermostat bypass bolts (2) to the water pump and tighten to 21 Nm (16 lb ft).
4. Connect the turbocharger coolant return hose (1) to the thermostat bypass pipe (3).




5. Install the oil fill tube bolt (3) and tighten to 25 Nm (18 lb ft).
6. Install the oil fill tube bracket bolt (4) and tighten to 25 Nm (18 lb ft)
7. Install the turbocharger coolant feed hose (2) and the engine coolant temperature sensor connector (1).
8. Install the fuel return line canister into the clip retainer at the top of the thermostat housing.




9. Install the fuel pressure valve bolt (1) and tighten to 25 Nm (18 lb ft)
10. Install the A/C compressor and power steering bracket.
11. Install the generator bracket. Refer to Generator Bracket Replacement Generator Bracket Replacement.
12. Install the drive belt tensioner. Refer to Drive Belt Replacement ()
13. Install the radiator fan. Refer to Fan Replacement (Fan Replacement).
14. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Radiator Inlet Hose Replacement).