Water Passage Replacement

Water Passage Replacement

1. Drain the engine coolant Service and Repair.

2. Remove the intake manifold.

3. Remove the drive belt auto-tensioner Drive Belt Auto-Tensioner Removal/Installation.

4. Remove the alternator Removal and Replacement.

5. Remove the A/C condenser fan shroud assembly.

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

7. Remove the connecting pipe mounting bolts (A), then remove the connecting pipe (B).





8. Disconnect the lower radiator hose (C) and the water bypass hose (D). Remove the harness clamp (E).

9. Remove the water passage assembly.






10. Remove the thermostat housing assembly (A) from the water passage (B).






11. Remove the water pump (C) from the water passage Water Pump Replacement.

12. Clean and dry the water passage mating surfaces.

13. Install the water pump (A) to the water passage (B) Water Pump Replacement.





14. Install the thermostat housing assembly (C) with a new O-ring (D) to the water passage.

15. Apply liquid gasket (P/N 08717-0004, 08718-0003, 08718-0004, 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 3 mm (0.12 in) diameter bead 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.





16. Install the water passage assembly (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.





17. Install the connecting pipe (A) with a new O-ring (B), then tighten the bolt (C).





18. Connect the lower radiator hose (D) and the water bypass hose (E), then install the harness clamp (F).

19. Tighten the bolt (G) securing the connecting pipe.

20. Install the A/C compressor.

21. Install the A/C condenser fan shroud assembly.

22. Install the alternator.

23. Install the drive belt auto-tensioner Drive Belt Auto-Tensioner Removal/Installation.

24. Install the intake manifold.

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

26. Clean up any spilled engine coolant.