I know that there is a good write up already in the FAQs written by wi65td, but I just did the 97 cooling mod, and took some pics at the same time. Here is how it went for me.


Before you get started, make sure that you have some gasket sealer, a good gasket scraper, a wire brush, an 18, 15, 13, and 10 mm deep socket – you will get nowhere without these. Make sure you give yourself lots of time as well. This upgrade (crossover and pump) took me 8 hours (this includes a lunch break, and a ridiculous amount of time to get the old gasket off of the pump backer plate.
Take a pic of your engine before disassembly – this is a huge help later on. http://www.dieselplace.com/forum/garage_images/i8307.jpg
Drain the coolant and disconnect the batteries. Remove the upper shroud, radiator (if you need to clean it out), the lower skid plate, and the lower shroud.
Loosen the bolts that hold the fan onto the water pump while you still have the serpentine belt installed.
Remove the serpentine belt. http://www.dieselplace.com/forum/garage_images/i8536.jpg
Remove the support bracket holding the power steering pump in place. This consists of 2 bolts behind the pulley (easy to get to), one bolt into the block on the front, and one bolt that threads into the side of the block – this bolt is easy to get out with a u-joint adapter http://www.dieselplace.com/forum/garage_images/i8537.jpg
Remove the air conditioning compressor and the vacuum pump (pretty straight forward – just a couple of bolts) – lay the compressor to the side but make sure you hold it up with mechanics wire to keep the hoses from breaking.http://www.dieselplace.com/forum/garage_images/i8538.jpg
Remove the alternator (a couple of bolts) http://www.dieselplace.com/forum/garage_images/i8539.jpg
Disconnect everything from the crossover tube (heater quick coupler and the CTS). Pray to the Gods, or make a sacrifice in hopes that you don’t break the magnesium quick connect – it worked for me. http://www.dieselplace.com/forum/garage_images/i8540.jpg
Remove the crossover tube. http://www.dieselplace.com/forum/garage_images/i8541.jpg
Remove the water pump and backer plate http://www.dieselplace.com/forum/garage_images/i8542.jpg
Clean up the gasket mating surfaces on the block and backer plate. (This is what took a LOOOONG time for me to do)
Install new water pump on old backer plate with supplied gasket. Use Teflon tape on the threads of the bolts going into the block. Put gasket sealer on the block and the back of the backer plate. Install new water pump. http://www.dieselplace.com/forum/garage_images/i8543.jpg
Notch out the bracket holding up the belt tensioner to accommodate the fat new crossover. I notched out my bracket using an angle grinder. CAREFULLY bend the fuel return line towards the IP to make as much room for the new crossover as possible.
Install new crossover tube with new gaskets and sealer.
Install CTS and quick connect into the new crossover using Teflon tape on both pieces.
Work your way backwards to reinstall the accessories, belt, radiator, shroud, and skid plate.
Check for leaks and bleed out the cooling system using the air bleed at the top of the crossover.
Congratulations, you have now upgraded to a HO cooling system! http://www.dieselplace.com/forum/garage_images/i8544.jpg

Mods - feel free to add this to the FAQs for people to read before they tackle this upgrade...

Nice work, and thanks for documenting it!

BTW, did you ever replace the timing chain?

Nice work, and thanks for documenting it!

BTW, did you ever replace the timing chain?

Thanks!

No, I didn't replace the chain. In hindsight I maybe should have, but I am having no timing problems right now (knock on wood), so I figured I would just hold off on that for the time being....

Now with this upgrade what rad hose is to be used? and t-stats temp should be?

Get the upper rad hose for a 97, and get a new chunk of hose to run from the crossover to the pump - the distance is a little longer on the 97's than it is on the 94's...

As for the stats, I believe it should be a 180* and a 195* but someone else may have to correct me on that....