Water Outlet Removal and Installation

Water Outlet Removal and Installation

Removal

1. Drain the engine coolant. Service and Repair

2. Remove the air cleaner housing assembly. Service and Repair

3. Remove the heater hose clamp bracket mounting bolt (A) and the harness holder mounting bolt (B).

4. Disconnect the water bypass hose (C), then remove the harness holder (D) from the bracket.






5. Disconnect the upper radiator hose (A) and the water bypass hose (B).






6. Disconnect the engine coolant temperature (ECT) sensor 1 connector (A), then remove the water outlet.






7. Remove ECT sensor 1 (A) and the water bypass hose (B).






Installation

1. Install ECT sensor 1 (A) with new O-ring (B).

2. Install the water bypass hose (C).

3. Remove all of the old liquid gasket from the water outlet mating surfaces, the bolts, and the bolt holes.

4. Clean and dry the water outlet mating surfaces.






5. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009) to the cylinder head mating surface of the water outlet and to the inside edge of the bolts holes. Install the component within 5 minutes of applying the liquid gasket.
NOTE:

- Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead along the broken line (A).

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





6. Install the water outlet, then reconnect the ECT 1 connector (A).
NOTE:

- Wait at least 30 minutes before filling the engine with oil.

- Do not run the engine for at least 3 hours after installing the chain case.





7. Install the upper radiator hose (A) and the heater hose (B).






8. Install the harness holder (A), then tighten the harness holder mounting bolt (B) and the heater hose clamp bracket mounting bolt (C).

9. Install the water bypass hose (D).

10. Clean up any spilled engine coolant.

11. Install the air cleaner housing assembly. Service and Repair

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