Coolant Outlet: Service and Repair

Water Outlet Replacement (LCV, LTG)

Special Tools

BO-38185 - Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill).

2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (LCV) Intake Manifold Cover ReplacementIntake Manifold Cover Replacement (LTG) Intake Manifold Cover Replacement.

3. Remove the battery tray. Refer to Battery Tray Replacement Service and Repair.




4. Disconnect the engine coolant temperature (ECT) sensor connector (3) from the water outlet (2).

5. Remove the following hoses from the water outlet:

* Radiator inlet hose (1).

* Heater inlet hose (4).

* Heater outlet hose (5).

6. Remove the secondary air injection inlet hose. Refer to Secondary Air Injection Pump Inlet Hose Replacement Secondary Air Injection Pump Inlet Hose Replacement.




7. Remove the thermostat bypass hose (2) from the water outlet (3).




8. Remove the water outlet fasteners (1) and remove the water outlet (2).

9. Discard the water outlet seal (1).

Installation Procedure




1. Install the water outlet (2) into position with a NEW seal (1).

Caution: Refer to Fastener Caution Fastener Caution.

2. Install the water outlet fasteners (3) and tighten to 12 Nm (106 lb in).




3. Install the thermostat bypass hose (2) to the water outlet (3).

4. Install the secondary air injection inlet hose. Refer to Secondary Air Injection Pump Inlet Hose Replacement Secondary Air Injection Pump Inlet Hose Replacement.




5. Connect the engine coolant temperature (ECT) sensor connector (3) to the water outlet (2).

6. Install the following hoses to the water outlet:

* Radiator inlet hose (1).

* Heater inlet hose (4).

* Heater outlet hose (5).

7. Install the battery tray. Refer to Battery Tray Replacement Service and Repair.

8. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (LCV) Intake Manifold Cover ReplacementIntake Manifold Cover Replacement (LTG) Intake Manifold Cover Replacement.

9. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill).

10. Start the engine and check for coolant leaks.