Water Outlet Removal/Installation

Water Outlet Removal and Installation

Removal

1. Drain the engine coolant Service and Repair.

2. Remove the air cleaner 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 ECT sensor 1 connector (A), then remove the water outlet (B).






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






Installation

1. Install ECT sensor 1 (A) with a 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, 08718-0003, 08718-0004, or 08718-0009) to the cylinder head mating surface of the water outlet and to the inside edge of the threaded bolts holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 2.5 mm (0.098 in) diameter dead of liquid gasket 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 connect the ECT sensor 1 connector (A).

NOTE:

- After assembly, 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 outlet.





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






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





9. Connect the water bypass hose (D).

10. Install the air cleaner Service and Repair.

11. Refill the radiator with engine coolant, and bleed the air from the cooling system.

12. Clean up any spilled engine coolant.