Water Passage Replacement
Water Passage Replacement1. Drain the engine coolant.
2. Remove the intake manifold.
3. Remove the upper radiator hose (A) and lower radiator hose (B).
4. Remove the water bypass hose (A) and ground cable (B).
5. Remove the harness holder mounting bolt (C), then remove the harness holder (D) from the bracket.
6. Remove the heater hoses.
7. Remove the engine wire harness connectors from the water passage.
^ Engine coolant temperature (ECT) sensor 1 connector
^ Engine coolant temperature (ECT) sensor 2 connector
^ Exhaust gas recirculation (EGR) valve connector
8. Remove the water passage (A) and connecting pipe (B).
9. Remove the EGR valve (A), ECT sensor 1 (B), ECT sensor 2 (C), thermostat cover (D), and thermostat (E).
10. Install the new rubber seal (F) onto the thermostat, then install the thermostat with pin (G) up, and install the thermostat cover.
11. Install the ECT sensor 1 and ECT sensor 2, using the new O-rings (H).
12. Install the EGR valve, using a new gasket (I).
13. Install the connecting pipe (A) and water passage (B), using the new O-rings (C) and new gaskets (D).
14. Install the heater hoses.
15. Install harness holder (A) to the bracket, then tighten the mounting bolt (B).
16. Install the water bypass hose (C) and ground cable (D).
17. Install the upper radiator hose (A) and lower radiator hose (B).
18. Install the intake manifold.
19. After installation, check that all tubes, hoses and connectors are installed correctly.
20. Refill the radiator with engine coolant, then bleed air from the cooling system.
21. Clean up any spilled engine coolant.