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Home >> Cadillac >> 2003 >> Seville SLS >> Repair and Diagnosis >> External Pages >> Different car >> Section 522 (Engine Cooling System) >> Repair Instructions >> Coolant Crossover Pipe Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Cadillac Seville. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Crossover Retaining Bolts
    GM550504Courtesy of GENERAL MOTORS CORP.
  1. With all 8 crossover retaining bolts inserted, slide the upper and lower water housing crossover gaskets onto the bolts.
    2. IMPORTANT: Care should be taken when installing the water housing bolts, so that the gaskets are in the correct position.
  2. Place the water housing crossover in position and hand start the bolts to hold the crossover in place.
    3. Fig 2: View of Water Housing Crossover Bolts Sequence
    GM522930Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Tighten the water housing crossover bolts.

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

  4. Connect the heater hose to the water housing crossover.
  5. Connect the cable harness clip to the water housing crossover.
    6. Fig 3: Identifying Water Pump Belt Tensioner to Water Crossover Bolts
    GM500274Courtesy of GENERAL MOTORS CORP.
  6. 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).

  7. Install the water pump. Refer to Water Pump Replacement .
    8. Fig 4: View Of Front Of Engine Compartment
    GM518337Courtesy of GENERAL MOTORS CORP.
  8. Position the J 38185  to the clamp in order to connect the outlet radiator hose (2) to the thermostat housing.
    9. Fig 5: Removing Hose Clamp
    GM518338Courtesy of GENERAL MOTORS CORP.
  9. Position the J 38185  (2) to the clamp in order to connect the inlet radiator hose (1) to the water housing crossover.
    10. Fig 6: View of MAP Sensor
    GM522699Courtesy of GENERAL MOTORS CORP.
  10. Install the MAP sensor.
  11. Connect the electrical connector to the MAP sensor.
  12. Install the EGR valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement in Engine Controls-4.6L.
    13. Fig 7: EGR Inlet Tube
    GM651462Courtesy 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.
  13. 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).

  14. Connect the EGR inlet pipe flange (3) to the water crossover.
  15. 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).

    16. Fig 8: Identifying Surge Tank Inlet Fitting
    GM522707Courtesy of GENERAL MOTORS CORP.
  16. Position the rear lift bracket to the water crossover.
  17. Install the rear lift bracket bolt.

    Tighten:  Tighten the rear lift bracket bolt to 24 N.m (18 lb ft).

  18. Install the surge tank inlet fitting.

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

    19. Fig 9: Identifying Fuel Rail Bracket Retaining Nut
    GM527521Courtesy of GENERAL MOTORS CORP.
  19. Connect the surge tank inlet hose to the fitting.
  20. 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).

    21. Fig 10: Identifying Fuel regulator Vacuum Tube & AIR Solenoid Vacuum Tube
    GM490599Courtesy of GENERAL MOTORS CORP.
  21. Connect the AIR solenoid vacuum tube (2) to the housing crossover.
  22. Connect the fuel regulator vacuum tube (1).
  23. Connect the brake booster vacuum tube.
  24. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls-4.6L.
  25. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-4.6L.
  26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.6L.
  27. Fill the cooling system. Refer to Draining and Filling Cooling System .
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