Coolant Line/Hose: Service and Repair

Thermostat Bypass Pipes Replacement

^ Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system.
2. Carefully remove the throttle body air inlet duct.
3. Remove the spark plug wires at the left bank.





4. Using the J 38185, reposition the hose clamp at the thermostat housing
5. Remove the upper radiator hose from the housing.





6. Disconnect the heater outlet hose from the thermostat bypass pipe (2).
7. Disconnect the throttle body inlet and outlet hoses from the thermostat bypass pipe (1).





8. Remove the thermostat bypass pipe-to throttle body nut.





9. Using the J 38185, reposition the hose clamp at the thermostat bypass pipe.
10. Disconnect the thermostat bypass pipe hose.





11. Remove the thermostat bypass pipe-to-engine front cover bolt.
12. Remove the thermostat bypass pipe.

Installation Procedure





1. Install the thermostat bypass pipe.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the thermostat bypass pipe-to-engine front cover bolt.
^ Tighten the bolt to 11 Nm (98 inch lbs.).





3. Connect the thermostat bypass pipe hose.
4. Using the J 38185, reposition and secure the hose clamp at the thermostat bypass pipe.





5. Install the thermostat bypass pipe to the throttle body stud.
6. Install the thermostat bypass pipe-to-throttle body nut.
^ Tighten the nut to 25 Nm (18 ft. lbs.)





7. Connect the heater outlet hose to the thermostat bypass pipe (2).
8. Connect the throttle body inlet and outlet hoses to the thermostat bypass pipe (1).
9. Connect the inlet hose at the thermostat housing.





10. Using the J 38185, reposition and install the inlet hose clamp at the thermostat housing.
11. Install the spark plug wires at the led bank.
12. Install the air cleaner assembly.
13. Fill the cooling system.
14. Inspect for leaks.