Water Crossover Replacement

Engine Coolant Crossover Pipe Replacement

Removal Procedure

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the air cleaner assembly.
4. Remove the throttle body.
5. Remove the EGR outlet pipe.





6. If equipped with AIR, remove the vacuum hose (3) from the AIR shut-off valve.





7. If equipped with AIR, remove the AIR shut-off valve fasteners.





8. If equipped with AIR, remove the AIR shut-off valve bracket bolts (2).
9. If equipped with AIR, remove the AIR shut-off valve from the bracket and the manifold pipe.
10. If equipped with AIR, clean the AIR shut-off valve gasket mating surfaces.
11. Install the engine support fixture. Refer to Engine Support Fixture.
12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
13. Remove the transmission filler tube. Refer to Transmission Fluid Filler Tube Replacement for the 4T65-E in automatic transaxle.
14. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
15. Remove the EGR inlet pipe from the right exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement.
16. Remove the frame assembly. Refer to Frame Removal.





17. If equipped with AIR, remove the AIR crossover pipe bolt (3).
18. If equipped with AIR, remove the AIR crossover pipe nut.

Important: DO NOT remove the right exhaust manifold from the vehicle.

19. Remove the right exhaust manifold from the right cylinder head and the left exhaust manifold. Position the manifold aside. Refer to Exhaust Manifold Replacement.
20. Lower the vehicle.
21. Remove the EGR valve and the EGR heat shield. Refer to Exhaust Gas Recirculation Valve Replacement.
22. Remove the radiator inlet hose from the coolant crossover. Refer to Radiator Inlet Hose Replacement.
23. Remove the heater inlet hose from the coolant crossover. Refer to Heater Hoses Replacement for the manual HVAC systems or Heater Hoses Replacement for the automatic HVAC systems.
24. Remove the throttle body coolant hose from the coolant crossover.





25. Remove the coolant crossover bolts (1-6).





26. Remove the coolant crossover.
27. Remove the coolant crossover gaskets.
28. Clean and inspect the coolant crossover gasket mating surfaces.

Installation Procedure





1. Install the new coolant crossover gaskets (1).





2. Install the coolant crossover.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.





3. Install the coolant crossover bolts (1-6).

Tighten
Tighten the bolts in sequence to 25 Nm (18 lb in).

4. Install the throttle body coolant hose to the coolant crossover.
5. Install the heater inlet hose to the coolant crossover.
6. Install the radiator inlet hose to the coolant crossover.
7. Install the EGR heat shield and the EGR valve.
8. Raise the vehicle.
9. Install the right exhaust manifold to the right cylinder head and the left exhaust manifold.





10. If equipped with AIR, install the AIR crossover pipe nut.

Tighten
Tighten the nut to 25 Nm (18 lb ft).

11. If equipped with AIR, install the AIR crossover pipe bolt (3).

Tighten
Tighten the bolt to 9 Nm (80 lb in).

12. Install the frame assembly.
13. Install the EGR inlet pipe to the right exhaust manifold.
14. Install the catalytic converter.
15. Install the transmission filler tube.
16. Lower the vehicle.
17. Remove the engine support fixture.





18. If equipped with AIR, install the AIR shut-off valve bracket, the gasket, and the valve to the manifold pipe.
19. If equipped with AIR, install the AIR shut-off valve bracket bolts (2).

Tighten
Tighten the bolts to 10 Nm (89 lb in).





20. If equipped with AIR, install the AIR shut-off valve fasteners.

Tighten
Tighten the fasteners to 9 Nm (80 lb in).





21. If equipped with AIR, install the vacuum hose (3) to the AIR shut-off valve.
22. Install the EGR outlet pipe.
23. Install the throttle body.
24. Install the air cleaner assembly.
25. Connect the negative battery cable.
26. Fill the cooling system.
27. Inspect the exhaust and the cooling systems for leaks.