Thermostat Housing Crossover Replacement

Thermostat Housing Crossover Replacement (LML)

Removal Procedure

1. Remove the radiator fan. Refer to Fan Replacement (Mechanical) (Service and Repair)Fan Replacement (Diesel) (Service and Repair).
2. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Outlet Hose Replacement (LGH, LML) (Radiator Hose).
3. Remove the drive belt tensioner. Refer to121520.
4. Remove the generator bracket. Refer to Generator Bracket Replacement (V6) (Service and Repair)Generator Bracket Replacement (V8) (Service and Repair)Generator Bracket Replacement (Diesel) (Service and Repair).
5. Remove the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement (HP2) (Air Conditioning Compressor Bracket Replacement)Air Conditioning Compressor Bracket Replacement (Non-HP2) (Air Conditioning Compressor Bracket Replacement)Air Conditioning Compressor Bracket Replacement (LGH, LML) (Air Conditioning Compressor Bracket Replacement).




6. Remove the fuel pressure service valve bolt (1) and reposition the fuel pressure service valve (2).




7. Disconnect the engine coolant temperature sensor (1).
8. Remove the EGR manifold cooling return hose (2) and the turbocharger coolant feed hose (3).




9. Unclip the fuel return dampener (1) and set aside.
10. Remove the oil fill tube bolt (3); the oil fill tube retainer bracket bolt (2); the oil fill tube (5) and the seal (4).




11. Remove the turbocharger coolant return hose (1) from the turbocharger coolant return pipe (2).




12. Remove the bolts (2) from 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. Clip the fuel return dampener (1) back into the retainer on top of the engine coolant outlet pipe.
6. Install the oil fill tube bolt (3) and tighten to 25 Nm (18 lb ft).
7. Install the oil fill tube bracket bolt (2) and tighten to 25 Nm (18 lb ft)




8. Install the EGR manifold cooling return hose (2); the turbocharger coolant feed hose (3) and the engine coolant temperature sensor connector (1).




9. Install the fuel pressure service valve bolts (1) and tighten to 25 Nm (18 lb ft)
10. Install the air conditioning bracket. Refer to Air Conditioning Compressor Bracket Replacement (HP2) (Air Conditioning Compressor Bracket Replacement)Air Conditioning Compressor Bracket Replacement (Non-HP2) (Air Conditioning Compressor Bracket Replacement)Air Conditioning Compressor Bracket Replacement (LGH, LML) (Air Conditioning Compressor Bracket Replacement).
11. Install the generator bracket. Refer to Generator Bracket Replacement (V6) (Service and Repair)Generator Bracket Replacement (V8) (Service and Repair)Generator Bracket Replacement (Diesel) (Service and Repair).
12. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (Service and Repair)
13. Install the radiator fan. Refer to Fan Replacement (Mechanical) (Service and Repair)Fan Replacement (Diesel) (Service and Repair).