Thermostat Housing Crossover Replacement (LLY, LBZ)

Thermostat Housing Crossover Replacement (LLY, LBZ)

Removal Procedure

1. Remove the radiator fan.
2. Remove the drive belt tensioner and generator bracket.
3. Remove the air conditioning (A/C) and power steering bracket.




4. Remove the fuel line bolt and position the fuel line aside.




5. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.




6. Remove the oil fill tube bolts and the oil fill tube.
7. Disconnect the coolant temperature sensor electrical connector.
8. Remove the exhaust gas recirculation (EGR) coolant pipe.




9. Remove the fuel pipe bracket bolt.
10. Disconnect the hose at the thermostat bypass pipe.
11. Disconnect the radiator inlet hose from the thermostat housing.
12. Remove the thermostat bypass bolts at the water pump.




13. Remove the 8 thermostat housing crossover bolts.
14. Remove the thermostat housing crossover.

Installation Procedure

1. Position the thermostat housing crossover.





Notice: Refer to Fastener Notice.

2. Install the 8 thermostat housing crossover bolts.

Tighten the thermostat housing crossover bolts to 25 N.m (18 lb ft).

3. Install the thermostat bypass bolts to the water pump.

Tighten to 21 N.m (16 lb ft).

4. Install the radiator inlet hose to the thermostat housing.
5. Connect the hose to the thermostat bypass pipe.




6. Install the fuel pipe bracket bolt.

Tighten the fuel pipe bracket bolt to 25 N.m (18 lb ft).

7. Install the EGR coolant pipe.
8. Connect the coolant temperature sensor electrical connector.




9. Install the oil fill tube bolts and the oil fill tube.

Tighten the oil fill tube bolts to 25 N.m (18 lb ft).




10. Compress the clamp and connect the turbocharger inlet cooling hose/pipe.




11. Position the fuel line and install the fuel line bolt.
12. Install the A/C and power steering bracket.
13. Install the drive belt tensioner and generator bracket.
14. Instal the radiator fan.