LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different car >> Section 412 (Engine Cooling System) >> Repair Instructions >> Coolant Crossover Pipe Replacement (8.1L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2004 GMC Yukon XL, 2004 GMC Yukon, 2004 Chevrolet Tahoe, 2004 Chevrolet Suburban, and 2004 Cadillac Escalade EXT. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Water Outlet, Bolts & Thermostat
    GM635643Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. If replacing the water crossover install the following:
    1. Thermostat (3)
    2. Water outlet (1)
    3. Water outlet bolts (2)

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

    2. Fig 2: View Of Engine Coolant Crossover & Gasket
    GM470698Courtesy 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).

    5. Fig 3: View Of Generator Bracket, Bolts, Nut & Stud
    GM751458Courtesy 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 Replacement (4.8L, 5.3L, and 6.0L Engines) or Generator Replacement (8.1L Engine) in Engine Electrical.
    10. Fig 4: View Of Bypass Hose (8.1L)
    GM846662Courtesy of GENERAL MOTORS CORP.
  10. Install the bypass hose.
  11. Position the bypass hose clamps at the water crossover and water pump.
    12. Fig 5: View Of Heater Inlet Hose At Water Crossover (8.1L)
    GM750694Courtesy 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.
    14. Fig 6: View Of Inlet Hose Clamp & Water Crossover
    GM751425Courtesy 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 .
scientia non olet · About LEMON Manuals