Coolant Outlet: Service and Repair

Coolant Manifold

Service Repair No - 26.30.64

Removal

CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

1. Disconnect the battery ground cable.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

2. Raise and support the vehicle.
3. Drain the cooling system.
4. Remove cooling fan.
5. Remove the cooling fan belt.
6. Remove the throttle body gasket.
7. Position the throttle body aside for access.
^ Disconnect the TP sensor electrical connector.
^ Release the coolant manifold throttle body electrical harness clip.





8. Disconnect the coolant manifold to radiator hose.
^ Remove the clip.





9. Disconnect the thermostat housing to radiator hose.
^ Remove the clip.
10. Disconnect the transmission cooler hoses.
^ Release the clip.
^ Remove the clip.





11. Remove the coolant manifold EGR valve hose.
^ Release the clip.
12. Disconnect both coolant manifold heater hoses.
^ Release the 2 clips.





WARNING: Fluid loss is unavoidable, use absorbent cloth or a container to collect the fluid.

CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

13. Release the coolant manifold.
^ Remove the 4 Torx(R) screws.
^ Remove and discard the 3 O-ring seals.





14. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
15. Remove the coolant manifold.

NOTE: Do not disassemble further if the component is removed for access only.

16. Remove the ECT sensor.
^ Remove the clip.
^ Remove and discard the O-ring seal.
17. Remove the thermostat housing.
^ Remove the 3 bolts.
^ Discard the O-ring seal.





Installation
1. Install the thermostat housing.
^ Clean the components.
^ Install a new O-ring seal.
^ Tighten the bolts to 10 Nm (7 ft. lbs).
2. Install the ECT sensor.
^ Clean the component mating faces.
^ Install a new O-ring seal.
^ Secure with the clip.
3. Connect the ECT sensor electrical connector.

NOTE: Lubricate the center seal with coolant to aid assembly.

4. Install the coolant manifold.
^ Clean the components.
^ Install new O-ring seals.
^ Tighten the Torx(R) screws to 10 Nm (7 ft. lbs).
5. Connect the remaining coolant hoses.
^ Secure with the clips.
6. Install the throttle body gasket.
7. Install the cooling fan drive belt.
8. Install cooling fan.
9. Connect the battery ground cable.
10. Refill and bleed the cooling system.