Diesel Data: Automotive Repair

Coolant Bypass Valve Replacement

TOOLS REQUIRED
J 39529 Heater Hose Pliers

REMOVAL PROCEDURE




1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
2. Remove the air cleaner assembly.
3. Recovery the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
4. Remove the accumulator.
5. Remove the hose clamps from the outlet hose and the inlet hose using the J 39529.
6. Disconnect the vacuum line from the bypass valve.




7. Remove the heater inlet hose and the outlet hose from the bypass valve.
8. Remove the bypass valve (3) from the vehicle.

INSTALLATION PROCEDURE




1. Install the bypass valve (3) to the vehicle.
2. Connect the heater inlet hose and the outlet hose to the bypass valve (5).




3. Install the hose clamps using the J 39529.
4. Connect the vacuum line to the bypass valve.
5. Install the accumulator.
6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
7. Fill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.