How do you replace coolant crossover pipe on a 2001 Pontiac Sunfire?

Answer 1

I'm assuming it's a 2.2 and you're talking about the black pipe that runs across the entire front of the engine:

1) Drain coolant... white drain plug at lower corner of rad (driver's side)

2) Disconnect hose clamps and pull off the 3 hoses

3) Remove sensor mounted in the pipe (passenger side near alternator). 3/4 inch deep socket.

4) Remove one mounting bolt holding pipe to bracket. 10mm. (top, driver's side)

5) Remove one stud/ bolt holding pipe to engine block. 13mm. It's hard to reach. Ordinarily you'd use a deep socket on a stud, but it wouldn't clear the motor mount so I used a shallow socket, but not pushed all the way down on the rachet handle. I had just enough clearance to fit over the stud and turn the rachet handle.

6) Remove passenger side tire

7) Remove splash shield in passenger side wheel well

8) Use a large pry bar on the square hole in belt tensioner to pull the tensioner down, then have a helper slip the drive belt off the alternator

9) Remove two wire connections from alternator

10) Remove 3 alternator mounting bolts and take alternator off the car

11) Pull the coolant pipe straight back toward passenger fender to detach from the block

12) Carefully work the pipe out of the engine compartment. It doesn't look like it will clear the motor mount, but it will. You don't need to remove the motor mount!

13) Use a new o- ring on the replacement pipe. Lubricate it so it slips nicely into place.

14) Use Teflon tape on the threads of the sensor

15) It's a good idea to replace the old spring clamps with worm gear clamps (the screw-to-tighten type)