Water Crossover Replacement

Water Crossover Replacement (8.11- Engine)

Removal Procedure





1. Drain the cooling system. Refer to Draining and Filling Cooling System.
2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory in Engine Mechanical - 8.1 L.
3. Reposition the inlet hose clamp at the water crossover.
4. Remove the inlet hose from the water crossover.





5. Reposition the heater inlet hose clamp at the water crossover.
6. Remove the heater inlet hose from the water crossover.





7. Reposition the bypass hose clamps at the water crossover and water pump.
8. Remove the bypass hose.





9. Remove the generator. Refer to Generator Replacement (4.8L, 5.3L, and 6.OL Engines) or Generator Replacement (8.1L Engine) in Engine Electrical.
10. Remove the power steering pump. Refer to Power Steering Pump Replacement (4.8 L, 5.3 L and 6.0 L Engines) or Power Steering Pump Replacement (8.1L) in Power Steering System.
11. Remove the generator bracket bolts and nut.
12. Remove the generator bracket stud.
13. Remove the generator bracket.





14. Remove the water crossover bolts.
15. Remove the water crossover.
16. Remove and discard the water crossover gaskets.





17. If replacing the water crossover remove the following:
17.1. Water outlet bolts (2)
17.2. Water outlet (1)
17.3. Thermostat (3)

Installation Procedure





Notice: Refer to Fastener Notice in Cautions and Notices.

1. If replacing the water crossover install the following:
1.1. Thermostat (3)
1.2. Water outlet (1)
1.3. Water outlet bolts (2)
- Tighten the water outlet bolts to 30 Nm (22 ft. lbs.).





2. Install NEW water crossover gaskets.
3. Install the water crossover.
4. Install the water crossover bolts.
- Tighten the water crossover bolts to 50 Nm (37 ft. lbs.).





5. Install the generator bracket.
6. Install the generator bracket stud.
- Tighten the generator bracket stud to 20 Nm (15 ft. lbs.).
7. Install the generator bracket bolts and nut.
- Tighten the generator bracket bolts and nut to 50 Nm (37 ft. lbs.).
8. Install the power steering pump. Refer to Power Steering Pump Replacement (4.8 L, 5.3 L and 6.0 L Engines) or Power Steering Pump Replacement (8.1L) in Power Steering System.
9. Install the generator. Refer to Generator Replacement (4.8L, 5.3L, and 6.OL Engines) or Generator Replacement (8.1L Engine) in Engine Electrical.





10. Install the bypass hose.
11. Position the bypass hose clamps at the water crossover and water pump.





12. Install the heater inlet hose to the water crossover.
13. Position the heater inlet hose clamp at the water crossover.





14. Install the inlet hose to the water crossover.
15. Position the inlet hose clamp at the water crossover.
16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory in Engine Mechanical - 8.1 L.
17. Fill the cooling system. Refer to Draining and Filling Cooling System.