Water Passage Replacement

Water Passage Replacement

1. Drain the engine coolant Service and Repair.

2. Clean any dirt off the quick connector (A), the thermostat cover, and the lower radiator hose.





3. Pull out the lock (B) by hand, then wiggle the quick connector loose, and remove it from the thermostat cover. Do not use any tools to remove the quick connector.

4. Remove the alternator.

5. Remove the splash shield.

6. Remove the A/C compressor without disconnecting the A/C hoses.

7. Remove the intake manifold.

8. Remove the connecting pipe mounting bolt (A) securing the connecting pipe (B).





9. Remove the connecting pipe and disconnect the water bypass hose (C) and the PCV hose (D).

10. Remove the water passage (A).





11. Remove the thermostat housing (B).

12. Remove the water pump Water Pump Replacement.

13. Install the water pump Water Pump Replacement.

14. Install the thermostat housing (A) with a new O-ring (B).





15. Clean and dry the water passage mating surfaces.

16. Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the engine block mating surface of the water passage and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





17. Install the water passage (A) with a new O-ring (B).

NOTE:

- Wait at least 30 minutes before filling the engine with coolant.
- Do not run the engine for at least 3 hours after installing the water passage.





18. Connect the water bypass hose (A) and the PCV hose (B).





19. Install the connecting pipe (C) with a new O-ring (D), then tighten the connecting pipe mounting bolt (E) securing the connecting pipe.

20. Install the intake manifold.

21. Install the A/C compressor.

22. Install the splash shield.

23. Install the alternator.

24. Check the quick connector (A) and the set ring (B) for cracks or damage. If the quick connector and/or the set ring are cracked or damaged, replace the quick connector.





25. Make sure the set ring is in place inside the quick connector. If the set ring is off the quick connector, replace the quick connector.

26. Replace a new O-ring (C) in the quick connector.

27. Check the lock (D). If the lock is damaged or deformed, replace it. When installing the new lock on the quick connector, push it straight down along the groove.

28. Clean the connecting surface of the thermostat cover (E), then apply clean engine coolant around the connecting surface.

29. Push the lock (A) down, then push the quick connector (B) onto the thermostat cover until you here it click.





30. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open Service and Repair.

31. Clean up any spilled engine coolant.