Water Passage Replacement

Water Passage Replacement
1. Drain the engine coolant.
2. Clean any dirt off the quick connector (A), thermostat cover, and lower radiator hose.





3. Pull out the lock (B) by hand, then wiggle the quick connector loose, and remove it from the thermostat cover. Do not use any tools to remove the quick connector.
4. Remove the alternator.
5. Remove the splash shield.
6. Remove the NC compressor without disconnecting the A/C hoses.
7. Remove the intake manifold.
8. Remove a bolt (A) securing the connecting pipe.





9. Remove the connecting pipe (B), water bypass hose (C), and positive crankcase ventilation (PCV) hose (D).
10. Remove the water passage (A).





11. Remove the thermostat housing (B).
12. Remove the water pump.
13. Clean and dry the water passage mating surfaces.
14. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0002, 08718-0003, or 08718-0009, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes.

NOTE:
^ Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
^ Do not run the engine for at least 3 hours after installing the water passage.





15. Install the water pump.
16. Install the thermostat housing (A) with a new O-ring (B).





17. Install the water passage (C) with a new O-ring (D).
18. Install the connecting pipe (A) with a new O-ring (B).





19. Install the water bypass hose (C), and PCV hose (D), then tighten a bolt (E) securing the connecting pipe.
20. Install the intake manifold.
21. Install the A/C compressor.
22. Install the splash shield.
23. Install the alternator.
24. Check the quick connector (A), and set ring (B) for cracks or damage. If the connector and/or set ring are cracked or damaged, replace the connector.





25. Make sure the set ring is in place inside the quick connector. If the set ring is off the connector, replace the quick connector.
26. Replace the Or-ring (C) In the quick connector.
27. Check the lock (D). If the lock is damaged or deformed, replace it. When installing the new lock on the connector, press it straight down along the groove.
28. Clean the connecting surface of the thermostat cover (E), then apply clean engine coolant around the connecting surface.
29. Push down the lock (A), then push the quick connector (B) onto the thermostat cover until you here it click.





30. After assembly, wait at least 30 minutes before filling the engine with coolant or oil.