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Water Crossover Assembly: Installation

  1. With all 8 water crossover retaining bolts inserted, slide the upper and lower water crossover gaskets onto the bolts. See Figure. Care should be taken when installing the water housing bolts, so that the gaskets are in the correct position.
  2. Place the water crossover assembly in position and hand start the bolts to hold the crossover in place. Tighten the water crossover assembly bolts to specification. See TORQUE SPECIFICATIONS . Connect the heater hose to the water crossover assembly.
  3. Connect the cable harness clip to the water housing assembly. Install the 2 bolts attaching the water pump belt tensioner to the water crossover assembly. Tighten the water pump belt tensioner bolts to specification. Install the water pump. See WATER PUMP . Install the outlet radiator hose to the thermostat housing.
  4. Install the inlet radiator hose to the water crossover assembly. Install the MAP sensor. Connect the electrical connector to the MAP sensor. Install the EGR valve. Hand start the NEW EGR inlet pipe-to-crossover pipe nut to prevent crossthreading. Tighten the EGR inlet pipe nut to specification. Connect the EGR inlet pipe flange to the water crossover assembly.
  5. Install the EGR inlet pipe-to-water crossover flange bolt. Tighten the EGR inlet pipe bolt to specification. Install the EVAP canister purge solenoid. Position the rear lift bracket to the water crossover. See Figure. Install the rear lift bracket bolt. Tighten the rear lift bracket bolt to specification.
  6. Install the surge tank inlet fitting. Tighten the surge tank inlet fitting to specification. Connect the surge tank inlet hose to the fitting. Connect the fuel rail bracket retaining nut to the rear lift bracket. Tighten the fuel rail bracket retaining nut to specification. Connect the AIR solenoid vacuum tube to the housing crossover assembly. Connect the fuel regulator vacuum tube. Connect the brake booster vacuum tube.
  7. Install the throttle body. THROTTLE BODY  under FUEL SYSTEMS. Install the fuel injector sight shield. Install the air cleaner assembly. Fill the cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEM.


  1. With all 8 crossover retaining bolts inserted, slide the upper and lower water housing crossover gaskets onto the bolts. See Figure. Care should be taken when installing the water crossover bolts, so that the gaskets are in the correct position.
  2. Place the water crossover assembly in position and hand start the bolts to hold the crossover in place. Tighten the water crossover assembly bolts to specification. See TORQUE SPECIFICATIONS . Connect the heater hose to the water crossover assembly.
  3. Connect the cable harness clip to the water housing assembly. Install the 2 bolts attaching the water pump belt tensioner to the water crossover assembly. Tighten the water pump belt tensioner bolts to specification. Install the water pump. See WATER PUMP . Install the outlet radiator hose to the thermostat housing.
  4. Install the inlet radiator hose to the water crossover assembly. Install the MAP sensor. Connect the electrical connector to the MAP sensor. Install the EGR valve. Hand start the NEW EGR inlet pipe-to-crossover pipe nut to prevent crossthreading. Tighten the EGR inlet pipe nut to specification. Connect the EGR inlet pipe flange to the water crossover assembly.
  5. Install the EGR inlet pipe-to-water crossover flange bolt. Tighten the EGR inlet pipe bolt to specification. Install the EVAP canister purge solenoid. Position the left engine mount strut bracket to the water crossover assembly. Install the bolts securing the left engine mount strut bracket to the water crossover. Tighten the left engine mount strut bracket to water crossover bolts to specification.
  6. Install the surge tank inlet fitting. Tighten the surge tank inlet fitting to specification. Install the secondary AIR pipe retaining bolt to the left engine mount strut bracket. Tighten the AIR pipe retaining bolt to specification. Connect the surge tank inlet hose to the surge tank inlet fitting. Position the left engine mount strut to the vehicle. Install the three bolts securing the engine mount strut to the radiator tie bar.
  7. Tighten the engine mount strut to radiator tie bar bolts to specification. Install the bolt securing the engine mount strut to the engine. Tighten the engine mount strut bolts to specification. Connect the AIR solenoid vacuum tube to the housing crossover assembly. Connect the fuel regulator vacuum tube. Connect the brake booster vacuum tube.
  8. Install the throttle body. THROTTLE BODY  under FUEL SYSTEMS. Install the fuel injector sight shield. Install the air cleaner assembly. Fill the cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEM.
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