Installation Procedure

With all 8 crossover retaining bolts inserted, slide the upper and lower water housing crossover gaskets onto the bolts.
Important: Care should be taken when installing the water housing bolts, so that the gaskets are in the correct position.
Place the water housing crossover in position and hand start the bolts to hold the crossover in place.

Fig 1: Placing Water Housing Crossover In Position
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Tighten the water housing crossover bolts.
Tighten

Tighten the water housing crossover bolts to 25 N.m (18 lb ft).
Connect the heater hose to the water housing crossover.
Connect the cable harness clip to the water housing crossover.

Fig 2: Tightening Water Housing Crossover Bolts
Courtesy of GENERAL MOTORS CORP.
Install the 2 bolts (3) attaching the water pump belt tensioner (1) to the water crossover.
Tighten

Tighten the water pump belt tensioner bolts to 10 N.m (89 lb in).
Install the water pump. Refer to WATER PUMP REPLACEMENT .

Fig 3: Installing Water Pump Belt Tensioner
Courtesy of GENERAL MOTORS CORP.
Position the J 38185 to the clamp in order to connect the outlet radiator hose (2) to the thermostat housing.

Fig 4: Connecting Outlet Radiator Hose To Thermostat Housing
Courtesy of GENERAL MOTORS CORP.
Position the J 38185 (2) to the clamp in order to connect the inlet radiator hose (1) to the water housing crossover.

Fig 5: Connecting Inlet Radiator Hose To Water Housing Crossover
Courtesy of GENERAL MOTORS CORP.
Install the MAP sensor.
Connect the electrical connector to the MAP sensor.
Install the EGR valve. Refer to EGR VALVE .

Fig 6: Installing MAP Sensor
Courtesy of GENERAL MOTORS CORP.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.
Hand start the NEW EGR inlet pipe-to-crossover pipe nut (1) to prevent crossthreading
Tighten

Tighten the EGR inlet pipe nut to 60 N.m (44 lb ft).
Connect the EGR inlet pipe flange (3) to the water crossover.
Install the EGR inlet pipe-to-water crossover flange bolt (2).
Tighten

Tighten the EGR inlet pipe bolt to 25 N.m (18 lb ft).
Install the EVAP emission canister purge valve. Refer to EVAP CANISTER PURGE SOLENOID .

Fig 7: Installing EGR Valve Inlet Pipe
Courtesy of GENERAL MOTORS CORP.
Position the rear lift bracket to the water crossover.
Install the rear lift bracket bolt.
Tighten

Tighten the rear lift bracket bolt to 24 N.m (18 lb ft).
Install the surge tank inlet fitting.
Tighten

Tighten the surge tank inlet fitting to 47 N.m (35 lb ft).

Fig 8: Installing Rear Lift Bracket & Bolt
Courtesy of GENERAL MOTORS CORP.
Connect the surge tank inlet hose to the fitting.
Connect the fuel rail bracket retaining nut to the rear lift bracket.
Tighten

Tighten the fuel rail bracket retaining nut to 4 N.m (35 lb in).

Fig 9: Connecting Surge Tank Inlet Hose To Fitting
Courtesy of GENERAL MOTORS CORP.
Connect the AIR solenoid vacuum tube (2) to the housing crossover.
Connect the fuel regulator vacuum tube (1).
Connect the brake booster vacuum tube.
Install the throttle body. Refer to THROTTLE BODY .
Install the fuel injector sight shield.
Install the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY .
Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .

Fig 10: Connecting Fuel Regulator Vacuum Tube & AIR Solenoid Vacuum Tube
Courtesy of GENERAL MOTORS CORP.