GM Service Manual Online
For 1990-2009 cars only

Engine Coolant Crossover Pipe Replacement LD8

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure


    Object Number: 1663944  Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  4. Remove the water pump drive belt. Refer to Water Pump Belt Replacement .
  5. Reposition the brake booster vacuum hose clamp at the water pump housing.
  6. Remove the brake booster vacuum hose from the water pump housing.

  7. Object Number: 1662566  Size: SH
  8. Remove the oil level indicator tube nut.
  9. Reposition the oil level indicator tube.

  10. Object Number: 1670281  Size: SH
  11. Remove the transaxle vent hose clip (1) from the bracket.

  12. Object Number: 1564198  Size: SH
  13. Remove the throttle body bolts.
  14. Remove the bracket.
  15. Remove the throttle body.
  16. Remove and discard the throttle body seal.

  17. Object Number: 1564205  Size: SH
  18. Loosen the throttle body plenum duct clamp.
  19. Remove and discard the throttle body plenum duct.

  20. Object Number: 1662136  Size: SH
  21. Remove the fuel rail bracket nut at the rear left lift bracket.

  22. Object Number: 1662132  Size: SH
  23. Reposition the surge tank inlet hose clamp at the fitting.
  24. Remove the surge tank inlet hose from the fitting.

  25. Object Number: 1564203  Size: SH
  26. Remove the engine coolant outlet fitting.
  27. Remove the rear left lift bracket bolt.
  28. Remove the rear left lift bracket.

  29. Object Number: 1564178  Size: SH
  30. Remove the exhaust gas recirculation (EGR) valve shield nuts.
  31. Remove the EGR valve shield.

  32. Object Number: 1564195  Size: SH
  33. Remove the EGR valve bolts.
  34. Remove the EGR valve.
  35. Remove and discard the EGR valve gasket.

  36. Object Number: 1665460  Size: SH
  37. Disconnect the engine harness electrical connector (1) from the engine valley electrical connector.

  38. Object Number: 1666841  Size: SH
  39. Disconnect the EGR inlet pipe nut from the exhaust manifold front pipe.
  40. Important: The EGR valve inlet pipe incorporates a crush seal connection at the water pump housing. The EGR valve inlet pipe must be replaced if disconnected from the water pump housing.

  41. Remove the EGR inlet pipe bolt from the water pump housing.
  42. Remove and discard the EGR inlet pipe.

  43. Object Number: 1564197  Size: SH
  44. Remove the evaporative emission (EVAP) canister purge solenoid valve bolt.
  45. Remove the EVAP canister purge solenoid valve.

  46. Object Number: 1564200  Size: SH
  47. Remove the manifold absolute pressure (MAP) sensor bracket bolt.
  48. Remove the MAP sensor bracket.
  49. Remove the MAP sensor.

  50. Object Number: 1664570  Size: SH
  51. Using the J 38185 , reposition the radiator inlet hose clamp (1) at the water pump housing.
  52. Remove the radiator inlet hose (2) from the water pump housing.

  53. Object Number: 1664571  Size: SH
  54. Using the J 38185 , reposition the radiator outlet hose clamp (1) at the thermostat housing.
  55. Remove the radiator outlet hose (2) from the thermostat housing.

  56. Object Number: 1662860  Size: SH
  57. Remove the water pump belt tensioner studs.
  58. Remove the water pump belt tensioner.

  59. Object Number: 1664574  Size: SH
  60. Reposition the heater outlet hose clamp (4) at the heater pipe.
  61. Remove the heater outlet hose (3) from the heater pipe.

  62. Object Number: 1564175  Size: SH
  63. Remove the water pump cover bolt and studs.
  64. Remove the water pump cover

  65. Object Number: 1564115  Size: SH
  66. Loosen the water pump housing bolts.
  67. Remove the water pump housing.

  68. Object Number: 1564117  Size: SH
  69. Remove the water pump housing gaskets and bolts.

  70. Object Number: 1564207  Size: SH
  71. With the water pump housing on the bench, remove the water pump bolts.
  72. Remove the water pump from the water pump housing.

  73. Object Number: 1564167  Size: SH
  74. Remove and discard the water pump O-ring.

Installation Procedure


    Object Number: 1564167  Size: SH
  1. Install a NEW water pump O-ring to the water pump.

  2. Object Number: 1564207  Size: SH
  3. Install the water pump.
  4. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the water pump bolts.
  6. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1564216  Size: SH
  7. With the water pump housing on the bench, install the bolts in the locations shown.
  8. • Bolt (1) length 40.7 mm (1.6024 in).
    • Bolts (2) length 92.0 mm (3.6220 in).
    • Bolts (3) length 109.0 mm (4.2913 in).
    • Bolts (4) length 115.0 mm (4.5276 in).

    Object Number: 1564217  Size: SH
  9. With the housing still on the bench, install the NEW water pump housing gasket onto the bolts.

  10. Object Number: 1564115  Size: SH
  11. Position the water pump housing to the engine and hand start the bolts.

  12. Object Number: 522930  Size: SH
  13. Tighten the water pump housing bolts.
  14. Tighten
    Tighten the bolts in the sequence shown to 25 N·m (18 lb ft).


    Object Number: 1564175  Size: SH
  15. Install the water pump cover.

  16. Object Number: 682832  Size: SH

    Important: Ensure the bolt is installed in the lower inboard position (1) and the studs are installed in the remaining position (2).

  17. Install the water pump cover bolt and studs.
  18. Tighten
    Tighten the bolt/studs to 10 N·m (89 lb in).


    Object Number: 1664574  Size: SH
  19. Install the heater outlet hose (3) to the heater pipe.
  20. Position the heater outlet hose clamp (4) at the heater pipe.

  21. Object Number: 1662860  Size: SH
  22. Position the water pump belt tensioner.
  23. Install the water pump belt tensioner studs.
  24. Tighten
    Tighten the studs to 10 N·m (89 lb in).


    Object Number: 1664571  Size: SH
  25. Install the radiator outlet hose (2) to the thermostat housing.
  26. Using the J 38185 , position the radiator outlet hose clamp (1) at the thermostat housing.

  27. Object Number: 1664570  Size: SH
  28. Install the radiator inlet hose (2) to the water pump housing.
  29. Using the J 38185 , position the radiator inlet hose clamp (1) at the water pump housing.

  30. Object Number: 1564200  Size: SH
  31. Install the MAP sensor.
  32. Install the MAP sensor bracket.
  33. Install the MAP sensor bracket bolt.
  34. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1564197  Size: SH
  35. Install the EVAP canister purge solenoid valve.
  36. Install the EVAP canister purge solenoid valve bolt.
  37. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1666841  Size: SH

    Important: The EGR valve inlet pipe incorporates a crush seal connection at the water pump housing. The EGR valve inlet pipe must be replaced if disconnected from the water pump housing.

  38. Hand start the NEW EGR inlet pipe nut at the exhaust manifold front pipe.
  39. Install the EGR inlet pipe and bolt to the water pump housing.
  40. Tighten

        • Tighten the nut to 60 N·m (44 lb ft).
        • Tighten the bolt to 25 N·m (18 lb ft).

    Object Number: 1665460  Size: SH
  41. Connect the engine harness electrical connector (1) to the engine valley electrical connector.

  42. Object Number: 1564195  Size: SH
  43. Install the NEW EGR valve gasket.
  44. Install the EGR valve.
  45. Install the EGR valve bolts.
  46. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1564178  Size: SH
  47. Install the EGR valve shield.
  48. Instal the EGR valve shield nuts.
  49. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1564203  Size: SH
  50. Position the rear left lift bracket to the water pump housing.
  51. Install the rear left lift bracket bolt.
  52. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  53. Install the engine coolant outlet fitting.
  54. Tighten
    Tighten the fitting to 47 N·m (35 lb ft).


    Object Number: 1662132  Size: SH
  55. Install the surge tank inlet hose to the fitting.
  56. Position the surge tank inlet hose clamp at the fitting.

  57. Object Number: 1662136  Size: SH
  58. Instal the fuel rail bracket nut at the rear left lift bracket.
  59. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 1564205  Size: SH

    Important: DO NOT use any type of sealant between the plenum and the water pump housing.

  60. Install a NEW throttle body plenum duct.
  61. Tighten the throttle body plenum duct clamp.
  62. Tighten
    Tighten the clamp to 2.25 N·m (20 lb in).


    Object Number: 1564198  Size: SH
  63. Install a NEW throttle body seal.
  64. Install the throttle body.
  65. Install the throttle body bracket.
  66. Install the throttle body bolts.
  67. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1670281  Size: SH
  68. Install the transaxle vent hose clip (1) to the bracket.

  69. Object Number: 1662566  Size: SH
  70. Position the oil level indicator tube.
  71. Install the oil level indicator tube nut.
  72. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 1663944  Size: SH
  73. Install the brake booster vacuum hose to the water pump housing.
  74. Position the brake booster vacuum hose clamp at the water pump housing.
  75. Install the water pump drive belt. Refer to Water Pump Belt Replacement .
  76. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
  77. Fill the cooling system. Refer to Cooling System Draining and Filling .
  78. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .