Tools Required

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to Cooling System Draining and Filling .



2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
3. Remove the generator. Refer to Generator Replacement .
4. Remove the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement .
5. Remove the power steering pump. Refer to Power Steering Pump Replacement .
6. Reposition the coolant recovery reservoir inlet hose clamp (1) at the coolant crossover.
7. Remove the coolant recovery reservoir inlet hose (2) from the coolant crossover.



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



10. Reposition the thermal bypass hose clamp at the crossover pipe.
11. Remove the thermal bypass hose from the crossover pipe.
12. Remove the heater inlet and outlet pipe mounting bracket bolt.
13. Remove the wiring harness mounting bracket nut at the stud on the coolant crossover pipe.
14. Remove the heat pipe retaining stud from the coolant crossover pipe.
15. Remove the heater inlet and outlet pipe from the coolant crossover pipe and set aside.



16. Remove the coolant crossover pipe bolts (1-4).
17. Remove the coolant crossover pipe.

Notice: Refer to Fastener Notice in the Preface section.




1. Position the coolant crossover pipe to the cylinder heads.
2. Install the coolant crossover pipe bolts (1-4).

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

3. Install the heater inlet and outlet pipe to the coolant crossover pipe.
4. Install the heat pipe retaining stud to the coolant crossover pipe.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

5. Install the wiring harness mounting bracket nut at the stud on the coolant crossover pipe.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

6. Install the heater inlet and outlet pipe mounting bracket bolt.

Tighten
Tighten the bolts to 25 N·m (18 lb in).




7. Install the thermal bypass hose to the crossover pipe.
8. Position the thermal bypass hose clamp at the crossover pipe.



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



11. Install the coolant recovery reservoir inlet hose (2) to the coolant crossover.
12. Position the coolant recovery reservoir inlet hose clamp (1) at the coolant crossover.
13. Install the power steering pump. Refer to Power Steering Pump Replacement .
14. Install the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement .
15. Install the generator. Refer to Generator Replacement .
16. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
17. Fill the cooling system. Refer to Cooling System Draining and Filling .