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Home >> Chevrolet >> 2004 >> SSR >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Engine Cooling System) >> Repair Instructions >> Water Crossover Replacement (8.1L Engine) >> Installation Procedure
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Installation Procedure

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NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. If replacing the water crossover install the following:
    1. 1.1. Thermostat (3)
    2. 1.2. Water outlet (1)
    3. 1.3. Water outlet bolts (2)

      Tighten 

      Tighten the bolts to 30 N.m (22 lb ft).

    Fig 1: Installing Thermostat
    G02117766Courtesy of GENERAL MOTORS CORP.
  2. Install NEW water crossover gaskets.
  3. Install the water crossover.
  4. Install the water crossover bolts.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

    Fig 2: Installing Water Crossover
    G02117767Courtesy of GENERAL MOTORS CORP.
  5. Install the generator bracket.
  6. Install the generator bracket stud.

    Tighten 

    Tighten the stud to 20 N.m (15 lb ft).

  7. Install the generator bracket bolts and nut.

    Tighten 

    Tighten the bolts and nut to 50 N.m (37 lb ft).

  8. Install the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (4.8L, 5.3L AND 6.0L) or POWER STEERING PUMP REPLACEMENT (8.1L) in Power Steering System.
  9. Install the generator. Refer to GENERATOR (4.8L, 5.3L & 6.0L ENGINES) or GENERATOR (8.1L ENGINE) in Engine Electrical.
    Fig 3: Installing Generator Bracket
    G02117768Courtesy of GENERAL MOTORS CORP.
  10. Install the bypass hose.
  11. Position the bypass hose clamps at the water crossover and water pump.
    Fig 4: Installing Bypass Hose
    G02117769Courtesy of GENERAL MOTORS CORP.
  12. Install the heater inlet hose to the water crossover.
  13. Position the heater inlet hose clamp at the water crossover.
    Fig 5: Installing Heater Inlet Hose To Water Crossover
    G02117770Courtesy of GENERAL MOTORS CORP.
  14. Install the inlet hose to the water crossover.
  15. Position the inlet hose clamp at the water crossover.
  16. Install the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT -- ACCESSORY in Engine Mechanical - 8.1 L.
  17. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
    Fig 6: Installing Inlet Hose To Water Crossover
    G02117771Courtesy of GENERAL MOTORS CORP.
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