Removal and Replacement

Engine Coolant Crossover Pipe Replacement

Removal Procedure




1. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
2. Remove the generator bracket. Refer to Generator Bracket Replacement (LG5 without Belt Tensioner) Generator Bracket Replacement (LG5 without Belt Tensioner)Generator Bracket Replacement (LG5 without A/C) Generator Bracket Replacement (LG5 without A/C)Generator Bracket Replacement (LG5 with A/C) Generator Bracket Replacement (LG5 with A/C)Generator Bracket Replacement (L18) Generator Bracket Replacement (L18) in Engine Electrical.
3. Remove the power steering pump. Refer to Power Steering Pump Replacement (LG5 and JE4) Power Steering Pump Replacement (LG5 and JE4)Power Steering Pump Replacement (LG5 and JE3) Power Steering Pump Replacement (LG5 and JE3)Power Steering Pump Replacement (L18 ) Power Steering Pump Replacement (L18 ) in Power Steering System.
4. If equipped with regular production option (RPO) KZX, remove the air compressor bracket nuts at the power steering pump bracket.




5. Remove the power steering pump bracket bolts, nut, and stud.
6. Remove the power steering pump bracket.




7. Loosen the inlet hose clamp (2) at the coolant crossover.
8. Remove the inlet hose (1) from the coolant crossover.




9. Reposition the thermostat bypass hose clamps at the coolant crossover and water pump.
10. Remove the thermostat bypass hose.




11. Loosen the heater inlet pipe hose clamp.
12. Remove the heater inlet pipe bracket bolt.
13. Remove the heater inlet hose pipe nut at the coolant crossover.
14. Remove the heater inlet pipe.




15. Remove the coolant crossover bolts.
16. Remove the coolant crossover.
17. Remove and discard the coolant crossover gaskets.
18. Clean and inspect the coolant crossover. Refer to Water Crossover Cleaning and Inspection (C/K/G/C3500HD) Water Crossover Cleaning and Inspection (Medium Duty) in Engine Mechanical - 3.1 L Unit Repair.

Installation Procedure




1. Install new coolant crossover gaskets and the crossover into position.
Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the coolant crossover bolts.

Tighten the coolant crossover bolts to 50 Nm (37 lb ft).




3. Install the heater inlet pipe.
4. Install the heater inlet pipe bracket bolt.
5. Install the heater inlet hose pipe nut at the coolant crossover.

* Tighten the heater inlet pipe bracket bolt to 35 Nm (26 lb ft).
* Tighten the heater inlet pipe nut to 30 Nm (22 lb ft).

6. Tighten the heater inlet pipe hose clamp.

Tighten the heater inlet pipe clamp to 5 Nm (44 lb in).




7. Install the thermostat bypass hose.

Important: Properly position the bypass hose clamps to avoid water pump pulley interference.


8. Position the thermostat bypass hose clamps at the coolant crossover and water pump.




9. Install the inlet hose (1) to the coolant crossover.
10. Tighten the inlet hose clamp (2) at the coolant crossover.

Tighten the inlet hose clamp to 5 Nm (44 lb in).




11. If equipped with RPO KZX, install the air compressor bracket nuts at the power steering pump bracket.

Tighten the air compressor bracket nuts to 67 Nm (49 lb ft).

12. Install the power steering pump. Refer to Power Steering Pump Replacement (LG5 and JE4) Power Steering Pump Replacement (LG5 and JE4)Power Steering Pump Replacement (LG5 and JE3) Power Steering Pump Replacement (LG5 and JE3)Power Steering Pump Replacement (L18 ) Power Steering Pump Replacement (L18 ) in Power Steering System.
13. Install the generator bracket. Refer to Generator Bracket Replacement (LG5 without Belt Tensioner) Generator Bracket Replacement (LG5 without Belt Tensioner)Generator Bracket Replacement (LG5 without A/C) Generator Bracket Replacement (LG5 without A/C)Generator Bracket Replacement (LG5 with A/C) Generator Bracket Replacement (LG5 with A/C)Generator Bracket Replacement (L18) Generator Bracket Replacement (L18) in Engine Electrical.
14. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.