Hot Water Bypass Valve Replacement (With RPO Code C36)

HOT WATER BYPASS VALVE REPLACEMENT (WITH RPO CODE C36)

TOOLS REQUIRED
J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. Remove the air cleaner.
2. Remove the upper fan shroud.




3. Drain the engine coolant.
4. Disconnect the vacuum hose from the water bypass valve.
5. Using the J 38185, reposition the heater inlet hose (8) clamp from the water bypass valve.
6. Remove the heater inlet hose (8) from the water bypass valve.
7. Using the J 38185, reposition the heater outlet hose (7) clamp from the water bypass valve.
8. Remove the heater outlet hose (7) from the water bypass valve.
9. Using the J 38185, reposition the heater inlet hose (3) clamp from the water bypass valve.
10. Remove the heater inlet hose (3) from the water bypass valve.
11. Using the J 38185, reposition the heater outlet hose (4) clamp from the water bypass valve.
12. Remove the heater outlet hose (4) from the water bypass valve.
13. Using the J 38185, reposition the auxiliary heater outlet hose clamp from the water bypass valve.
14. Remove the auxiliary heater outlet hose (5) from the water bypass valve.
15. Using the J 38185, reposition the auxiliary heater outlet hose clamp (6) from the water bypass valve.
16. Remove the auxiliary heater outlet hose (10) from the water bypass valve.
17. Remove the bolt that retains the water bypass valve to the heater assembly.
18. Remove the water bypass valve.

INSTALLATION PROCEDURE




1. Install the water bypass valve to the heater assembly.
2. Install the bolt (3) that retains the water bypass valve to the heater assembly.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the bolt to 4 N.m (35 lb in).

3. Install the auxiliary heater outlet hose (5) to the water bypass valve.
4. Using the J 38185, reposition the auxiliary heater outlet hose clamp to the water bypass valve.
5. Install the auxiliary heater outlet hose (10) to the water bypass valve.
6. Using the J 38185, reposition the auxiliary heater outlet hose clamp (6) to the water bypass valve.
7. Install the heater outlet hose (4) to the water bypass valve.
8. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve.
9. Install the heater inlet hose (3) to the water bypass valve.
10. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve.
11. Install the heater outlet hose (7) to the water bypass valve.
12. Using the J 38185, reposition the heater inlet hose clamp to the water bypass valve.
13. Install the heater inlet hose (8) to the water bypass valve.
14. Using the J 38185, reposition the heater outlet hose clamp to the water bypass valve.
15. Connect the vacuum hose to the water bypass valve.
16. Fill the cooling system.
17. Install the upper fan shroud.
18. Install the air cleaner.