Water Passage Replacement

Water Passage Replacement

1. Drain the engine coolant.
2. Remove the splash shield.
3. Clean any dirt off the quick connector (A), the thermostat cover, and the lower radiator hose.





4. 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.
5. Remove the A/C compressor without disconnecting the A/C hoses.
6. Remove the alternator.
7. Remove the drive belt auto-tensioner.
8. Remove the intake manifold.
9. Remove the connecting pipe mounting bolts (A) securing the connecting pipe (B).





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





12. Remove the thermostat housing (B).
13. Remove the water pump.
14. Install the water pump.
15. Install the thermostat housing (A) with a new O-ring (B).





16. Clean and dry the water passage mating surfaces.
17. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the water passage. Install the component within 5 minutes of applying the liquid gasket.





18. Install the water passage (A) with a new O-ring (B).





19. Install the water bypass hose (A) and the PCV hose (B).





20. Install the connecting pipe (C) with a new O-ring (D), then tighten the connecting pipe mounting bolts (E) securing the connecting pipe.
21. Install the intake manifold.
22. Install the drive belt auto-tensioner.
23. Install the alternator.
24. Install the A/C compressor.
25. Install the splash shield.
26. 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.





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





32. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.