Coolant Line/Hose: Service and Repair

Engine Coolant Crossover Pipe Replacement (LZ4) (3.5L)

Removal Procedure




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Remove the battery. Refer to Battery Replacement (Battery Replacement).
3. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
5. Remove the ECT sensor.
6. Remove the radiator inlet and outlet hoses from the crossover pipe.
7. Disconnect the wiring harness ground terminal from the crossover pipe.




8. Remove the thermostat housing and thermostat from the crossover pipe.




9. Remove the crossover pipe bolts and crossover pipe.

Installation Procedure




1. Clean and dry the area before installing new seals.
2. Install the crossover pipe.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the crossover pipe bolts and tighten to 22 Nm (16 lb ft).
4. Install the thermostat and thermostat housing and tighten the bolts to 12 Nm (106 lb in).
5. Connect the coolant hoses at the crossover pipe.
6. Connect the wiring harness ground terminal to the crossover pipe and tighten the nut to 12 Nm (106 lb in).




7. Apply thread sealant (Saturn P/N 21485277) Loctite (TM) 242 threadlocker, or equivalent, to sensor threads.
8. Install the ECT sensor and tighten to 18 Nm (13 lb ft).
9. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
10. Install the battery. Refer to Battery Replacement (Battery Replacement).
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
Tighten the battery terminal bolt to 17 Nm (13 lb ft).
12. Fill the coolant. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).