Heater Return Pipe Assembly

Removal

Caution: MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE TO BE REMOVED.





1. Raise vehicle.
2. Drain cooling system as directed in "Engine Coolant Check and Replacement."





3. Remove right front road wheel.
4. Remove right upper wheelhouse panel.





5. Remove right wheelhouse side splash shield (left hand shown).





6. Place a 1 in. x 1 in. x 2 in. long block of wood (1) between the torque strut and cradle.

Important: Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.






7. Move heater outlet clamp and hose from heater core outlet pipe.

Caution: TO PREVENT PERSONAL INJURY, DO NOT STAND UNDER HEATER CORE OUTLET WHEN REMOVING HOSE BECAUSE SOME COOLANT WILL LEAK OUT AFTER HOSE IS REMOVED.





8. Lower vehicle.
9. Remove three engine mount to front cover nuts and two engine mount to midrail bracket nuts. Allow the powertrain to rest on the block of wood. Remove mount.





10. Raise vehicle.
11. Remove four bracket to midrail bolts from engine side of bracket and three bracket to midrail bolts from wheelhouse side of bracket. Remove bracket.





12. Open fuel vapor line clamps holding heater return line.
13. Remove fuel vapor line clip from stud.





14. Lower vehicle.
15. Remove remaining clamp and clip from midrail.
16. Remove washer bottle bolt and move washer bottle aside.
17. Remove hoses from coolant surge tank and heater return pipe.





18. Remove heater return pipe from vehicle.

Installation





1. Transfer hose clamp to new return pipe.
2. Install heater return pipe behind engine and into position at surge tank.
3. Raise vehicle.
4. Position pipe in front of dash clamps and clips on studs. Close all clamps.





5. Install hose to heater core outlet. Position clamp at 6 o'clock.





6. Lower vehicle.
7. Position pipe in mid-rail clamp and close.
8. Install hoses and clamps to bottle and pipe position clamps at 3 o'clock.
9. Install washer bottle and bolt.





10. Install midrail bracket.
11. Raise vehicle.
12. Hand start all midrail bracket bolts.
13. Tighten and torque all bolts.
^ Torque: 30 Nm (22 lb ft)





14. Lower vehicle.

Notice: To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.

15. Install the two engine mount to midrail bracket nuts first. Next, install the three engine mount to engine front cover nuts.
Remove the block of wood from under the torque strut after the upper mount assembly is installed.

Engine Mount-to-Front Cover:
^ Torque: 50 Nm (38 lb ft)

Engine Mount-to-Mid Rail Bracket:
^ Torque: 50 Nm (38 lb ft)





16. Raise vehicle.
17. Install upper wheelhouse panel.





18. Install wheelhouse side splash shield (left hand shown).
19. Install road wheel.
^ Torque: 140 Nm (103 lb ft)

20. Close radiator drain valve and install engine block drain.





21. Lower vehicle.
22. Fill cooling system and leak check as directed in "Engine Coolant Check and Replacement."
23. Install and tighten pressure cap.

Installation




1. Transfer hose clamp to new return pipe.
2. Install heater return pipe behind engine and into position at coolant recovery reservoir.
3. Raise vehicle.
4. Position pipe in front of dash clamps and clips on studs. Close all clamps.





5. Install hose to heater core outlet. Position clamp at 6 o'clock.





6. Lower vehicle.
7. Position pipe in mid-rail clamp and close.
8. Install hoses and clamps to bottle and pipe position clamps at 3 o'clock.
9. Install washer bottle and bolt.





10. Install midrail bracket.
11. Raise vehicle.
12. Hand start all midrail bracket bolts.
13. Tighten and torque all bolts.
Torque: 30 Nm (22 lb ft)





14. Lower vehicle.

Notice: To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.

15. Install the two engine mount to midrail bracket nuts first. Next, install the three engine mount to engine front cover nuts.
Remove the block of wood from under the torque strut after the upper mount assembly is installed.
Engine Mount-to-Front Covers
Torque: 50 Nm (38 lb ft)
Engine Mount-to-Mid Rail Bracket:
Torque: 50 Nm (38 lb ft)
16. Raise vehicle.





17. Install upper wheelhouse panel.





18. Install wheelhouse side splash shield (left hand shown).
19. Install road wheel.
Torque: 140 Nm (103 lb ft)
20. Close radiator drain valve and install engine block drain.
21. Lower vehicle.





22. Fill cooling system and leak check as directed in "Engine Coolant Check and Replacement."
23. Install and tighten coolant recovery reservoir cap.