Water Outlet Housing Replacement
Water Outlet Housing Replacement (LH2)
Special Tools
J 38185 Hose Clamp Pliers
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
4. Remove the throttle body from the water outlet housing. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
5. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement (Service and Repair).
6. Remove the purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (Service and Repair).
7. Position the J 38185 to the hose clamps to remove the following hoses from the water outlet housing:
* The surge tank outlet hose
* The radiator hose
* The heater hose
* The bypass hose
8. Remove the bolts securing the water outlet housing to the cylinder heads. Discard the gasket.
9. Clean and inspect. Refer to Water Outlet Housing Cleaning and Inspection (Overhaul).
10. Remove the following components from the water outlet housing:
* The water crossover pipe plug
* The throttle body inlet heater hose fitting
Installation Procedure
1. Install a new water outlet housing gasket.
2. Place the water outlet housing in position and hand start the bolts to hold the housing in place.
Caution: Refer to Fastener Caution (Fastener Caution).
3. Tighten the water outlet housing bolts and tighten to 25 Nm (18 lb ft).
4. Connect the following hoses to the water outlet housing:
* The bypass hose
* The heater hose
* The radiator hose
* The surge tank inlet hose
5. Position the J 38185 to the hose clamps to secure the hoses to the water outlet housing.
6. Install the purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (Service and Repair).
7. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement (Service and Repair).
8. Install the throttle body to the water outlet housing. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
11. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).