To service and repair the Thermostat Housing and replace the water crossover, first drain the cooling system off the Thermostat Housing, and make sure to remove the air cleaner assembly, fuel injector sight shield, and the brake booster vacuum tube from the water housing crossover. Remove the fuel regulator vacuum tube and the secondary air solenoid vacuum tube, and take off the
Throttle Body, left engine mount strut bracket and
EGR Valve. Remove the egr inlet pipe nut from the exhaust crossover, and remember that the EGR Valve inlet pipe has to be replaced if loosened from the water crossover. Unbolt the egr inlet pipe bolt and flange and remove it from the water crossover and throw the egr inlet pipe away. Next, take off the evap emission canister purge valve, disconnect the electrical connector from the
MAP Sensor, and remove the MAP Sensor. When using the j 38185 hose clamp plier (J 38185) remove the radiator inlet hose and outlet hose respectively from the water housing crossover and Thermostat Housing. Unbolt the
Water Pump belt tensioner from the water crossover, then detach it from the Water Pump and the two bolts that hold it to the Water Pump belt tensioner. Remove the cable harness clip from the water housing crossover and set it to the side, remove the heater hose from the water housing crossover, and remove the water housing crossover from the engine. Clean and inspect the water housing crossover and install it by inserting all eight crossover retaining bolts along to slant on putting the water housing crossover gaskets on the bolts. Put the water housing crossover on place and hand start the bolts then tighten them from top to bottom until you reach 25 nm (18 ft. Lbs.). Connect heater hose and cable harness clip to the water housing crossover, then bolt 2 in place holding Water Pump belt tensioner to the water crossover; tighten to 10 nm (89 inch lbs.). Install the Water Pump then with the j 38185 (J 38185) connect the radiator outlet hose to the Thermostat Housing and the radiator inlet hose to the water housing crossover. Mount the MAP Sensor and fit the electrical connect to it and install the EGR Valve. Hand start the new egr inlet pipe to crossover pipe nut to preclude crossthreading and tighten to 60 nm (44 ft. Lbs.). Attach egr inlet pipe flange to water crossover and install egr inlet pipe-to-water crossover flange bolt, torquing to 25 nm (18 ft. Lbs.). Lastly, connect the evap emission canister purge valve, the left engine mount strut bracket, connect the secondary air solenoid vacuum tube, fuel regulator vacuum tube, and brake booster vacuum tube before you install the Throttle Body, fuel injector sight shield and the air cleaner assembly, and fill the coolant system.