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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 648 (Engine Cooling System) >> Repair Instructions >> Water Crossover Replacement (8.1L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  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 the water outlet bolts to 30 N.m (22 lb ft).

  2. Install NEW water crossover gaskets.
  3. Install the water crossover.
  4. Install the water crossover bolts. Tighten the water crossover bolts to 50 N.m (37 lb ft).
  5. Install the generator bracket.
  6. Install the generator bracket stud. Tighten the generator bracket stud to 20 N.m (15 lb ft).
  7. Install the generator bracket bolts and nut. Tighten the generator bracket bolts and nut to 50 N.m (37 lb ft).
  8. Install the power steering pump.
  9. Install the generator.
  10. Install the bypass hose.
  11. Position the bypass hose clamps at the water crossover and water pump.
  12. Install the heater inlet hose to the water crossover.
  13. Position the heater inlet hose clamp at the water crossover.
  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.
  17. Fill the cooling system. Refer to Draining & Filling Cooling System .
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