Coolant Line/Hose: Service and Repair

Engine Coolant Crossover Pipe Replacement

Tools Required

J 38185 (SA9111E) Hose Clamp Pliers

Removal Procedure




1. Remove the intake manifold cover.
2. Remove the generator.
3. Remove the drive belt idler pulleys.
4. Remove the power steering pump.
5. Reposition the coolant recovery reservoir inlet hose clamp (1) at the coolant crossover.
6. Remove the coolant recovery reservoir inlet hose (2) from the coolant crossover.




7. Using the J 38185 release the tension on the hose clamp at the coolant crossover.
8. Remove the radiator inlet hose from the crossover pipe.




9. Reposition the thermal bypass hose clamp at the crossover pipe.
10. Remove the thermal bypass hose from the crossover pipe.




11. Remove the coolant crossover pipe bolts (1-4).
12. Remove the coolant crossover pipe.

Installation Procedure




1. Position the coolant crossover pipe to the cylinder heads.

Notice: Refer to Fastener Notice.

2. Install the coolant crossover pipe bolts (1-4).

Tighten the bolts to 50 N.m (37 lb ft).




3. Install the thermal bypass hose to the crossover pipe.
4. Position the thermal bypass hose clamp at the crossover pipe.




5. Install the radiator inlet hose to the crossover pipe.
6. Using a small flat-bladed screwdriver, release the hose clamp retention lock at the coolant crossover.




7. Install the coolant recovery reservoir inlet hose (2) to the coolant crossover.
8. Position the coolant recovery reservoir inlet hose clamp (1) at the coolant crossover.
9. Install the power steering pump.
10. Install the drive belt idler pulleys.
11. Install the generator.
12. Install the intake manifold cover.