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Home >> Isuzu >> 2007 >> i-290 LS, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 66 (Engine Cooling System) >> Repair Instructions >> Engine Coolant Crossover Pipe Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Cadillac DTS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Water Pump O-Ring Seal
    GM1564167Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW water pump O-ring to the water pump.
    2. Fig 2: Identifying Water Pump Bolts
    GM1564207Courtesy of GENERAL MOTORS CORP.
  2. Install the water pump.
    3. NOTE: Refer to Fastener Notice .
  3. Install the water pump bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    4. Fig 3: Idebtifying Water Pump Housing & Bolts
    GM1564216Courtesy of GENERAL MOTORS CORP.
  4. With the water pump housing on the bench, install the bolts in the locations shown.
    • Bolt (1) length 40.7 mm (1.6024 in).
    • Bolts (2) length 92.0 mm (3.6220 in).
    • Bolts (3) length 109.0 mm (4.2913 in).
    • Bolts (4) length 115.0 mm (4.5276 in).
    5. Fig 4: Removing/Installing Water Pump Housing Gaskets & Bolts
    GM1564217Courtesy of GENERAL MOTORS CORP.
  5. With the housing still on the bench, install the NEW water pump housing gasket onto the bolts.
    6. Fig 5: View Of Water Pump Housing
    GM1564115Courtesy of GENERAL MOTORS CORP.
  6. Position the water pump housing to the engine and hand start the bolts.
    7. Fig 6: View of Water Crossover Bolts
    GM522930Courtesy of GENERAL MOTORS CORP.
  7. Tighten the water pump housing bolts.

    Tighten:  Tighten the bolts in the sequence shown to 25 N.m (18 lb ft).

    8. Fig 7: View Of Water Pump Cover, Bolt & Studs
    GM1564175Courtesy of GENERAL MOTORS CORP.
  8. Install the water pump cover.
    9. Fig 8: Illustrating Proper Bolt & Stud Position
    GM682832Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure the bolt is installed in the lower inboard position (1) and the studs are installed in the remaining position (2).
  9. Install the water pump cover bolt and studs.

    Tighten:  Tighten the bolt/studs to 10 N.m (89 lb in).

    10. Fig 9: Identifying Heater Inlet & Outlet Hoses
    GM1664574Courtesy of GENERAL MOTORS CORP.
  10. Install the heater outlet hose (3) to the heater pipe.
  11. Position the heater outlet hose clamp (4) at the heater pipe.
    12. Fig 10: View Of Water Pump Drive Belt Tensioner
    GM1662860Courtesy of GENERAL MOTORS CORP.
  12. Position the water pump belt tensioner.
  13. Install the water pump belt tensioner studs.

    Tighten:  Tighten the studs to 10 N.m (89 lb in).

    14. Fig 11: View Of Radiator Outlet Hose At Thermostat Housing
    GM1664571Courtesy of GENERAL MOTORS CORP.
  14. Install the radiator outlet hose (2) to the thermostat housing.
  15. Using the J 38185  , position the radiator outlet hose clamp (1) at the thermostat housing. See Special Tools .
    16. Fig 12: View Of Radiator Inlet Hose & Clamp
    GM1664570Courtesy of GENERAL MOTORS CORP.
  16. Install the radiator inlet hose (2) to the water pump housing.
  17. Using the J 38185  , position the radiator inlet hose clamp (1) at the water pump housing. See Special Tools .
    18. Fig 13: Identifying MAP Sensor Bracket & Bolt
    GM1564200Courtesy of GENERAL MOTORS CORP.
  18. Install the MAP sensor.
  19. Install the MAP sensor bracket.
  20. Install the MAP sensor bracket bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    21. Fig 14: View Of EVAP Canister Purge Solenoid Valve & Bolt
    GM1564197Courtesy of GENERAL MOTORS CORP.
  21. Install the EVAP canister purge solenoid valve.
  22. Install the EVAP canister purge solenoid valve bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    23. Fig 15: Identifying EGR Valve Inlet Pipe
    GM1666841Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The EGR valve inlet pipe incorporates a crush seal connection at the water pump housing. The EGR valve inlet pipe must be replaced if disconnected from the water pump housing.
  23. Hand start the NEW EGR inlet pipe nut at the exhaust manifold front pipe.
  24. Install the EGR inlet pipe and bolt to the water pump housing.

    Tighten: 

    • Tighten the nut to 60 N.m (44 lb ft).
    • Tighten the bolt to 25 N.m (18 lb ft).

  25. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  26. Tighten the EGR inlet pipe nut.

    Tighten:  Tighten the nut to 60 N.m (44 lb ft).

  27. Lower the vehicle.
    28. Fig 16: View Of Engine Harness Electrical Connectors
    GM1665460Courtesy of GENERAL MOTORS CORP.
  28. Connect the engine harness electrical connector (1) to the engine valley electrical connector.
    29. Fig 17: View Of EGR Valve Bolts
    GM1564195Courtesy of GENERAL MOTORS CORP.
  29. Install the NEW EGR valve gasket.
  30. Install the EGR valve.
  31. Install the EGR valve bolts.

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

    32. Fig 18: Identifying EGR Bracket Shield Nuts
    GM1564178Courtesy of GENERAL MOTORS CORP.
  32. Install the EGR valve shield.
  33. Instal the EGR valve shield nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    34. Fig 19: Identifying Engine Coolant Outlet Fitting
    GM1564203Courtesy of GENERAL MOTORS CORP.
  34. Position the rear left lift bracket to the water pump housing.
  35. Install the rear left lift bracket bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  36. Install the engine coolant outlet fitting.

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

    37. Fig 20: View Of Surge Tank Inlet Hose/Pipe
    GM1662132Courtesy of GENERAL MOTORS CORP.
  37. Install the surge tank inlet hose to the fitting.
  38. Position the surge tank inlet hose clamp at the fitting.
    39. Fig 21: View Of Fuel Rail, Bracket & Bolts
    GM1662136Courtesy of GENERAL MOTORS CORP.
  39. Instal the fuel rail bracket nut (2) at the rear left lift bracket.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    40. Fig 22: Identifying Throttle Body Plenum Duct
    GM1564205Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: DO NOT use any type of sealant between the plenum and the water pump housing.
  40. Install a NEW throttle body plenum duct.
  41. Tighten the throttle body plenum duct clamp.

    Tighten:  Tighten the clamp to 2.25 N.m (20 lb in).

    42. Fig 23: View Of Throttle Body Assembly
    GM1564198Courtesy of GENERAL MOTORS CORP.
  42. Install a NEW throttle body seal.
  43. Install the throttle body.
  44. Install the throttle body bracket.
  45. Install the throttle body bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    46. Fig 24: Identifying Transaxle Vent Hose Clip
    GM1670281Courtesy of GENERAL MOTORS CORP.
  46. Install the transaxle vent hose clip (1) to the bracket.
    47. Fig 25: Oil Level Indicator Tube
    GM1662566Courtesy of GENERAL MOTORS CORP.
  47. Position the oil level indicator tube.
  48. Install the oil level indicator tube nut.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    49. Fig 26: View Of Brake Booster Vacuum Hose
    GM1663944Courtesy of GENERAL MOTORS CORP.
  49. Install the brake booster vacuum hose to the water pump housing.
  50. Position the brake booster vacuum hose clamp at the water pump housing.
  51. Install the water pump drive belt. Refer to Water Pump Belt Replacement .
  52. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
  53. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill)  or Draining and Filling Cooling System (Vac-N-Fill) .
  54. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
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