Coolant Line/Hose: Service and Repair
WATER PUMP INLET TUBE REMOVALWITHOUT AIR CONDITIONING
1. Partially drain cooling system.Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.
2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle.
WITH AIR CONDITIONING
If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF.
1. Disconnect battery negative cable.
2. Partially drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
3. Remove upper radiator hose clamp and hose at radiator.
4. Unplug wiring harness from A/C compressor.
5. Remove air cleaner assembly.
6. Remove accessory drive belt.
7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley.
8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket.
9. Disconnect throttle body cables.
10. Remove heater hose clamp and heater hose from heater hose coolant return tube.
11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring.
12. Remove bracket-to-intake manifold bolt.
13. Remove six bracket bolts.
14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position.
15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle.
WATER PUMP INLET TUBE INSTALLATION
WITHOUT AIR CONDITIONING
1. Position bypass hose clamps to center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Fill cooling system.
5. Start and warm the engine. Check for leaks.
WITH AIR CONDITIONING
1. Position bypass hose clamps to center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2- to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3- to 40 Nm (30 ft. lbs.) torque.
5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine.
7. Connect throttle body control cables.
8. Install oil dipstick mounting bolt.
9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque.
10. Install drive belt.
11. Install air cleaner assembly.
12. Install upper radiator hose to radiator.
13. Connect wiring harness to A/C compressor.
14. Connect battery negative cable.
15. Fill cooling system.
16. Start and warm the engine. Check for leaks.