Hot Water Bypass Valve Replacement (Without RPO Code C36)

HOT WATER BYPASS VALVE REPLACEMENT (WITHOUT 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 pipe (5) clamp from the water bypass valve.
6. Remove the heater inlet pipe from the water bypass valve.
7. Using the J 38185, reposition the heater outlet pipe (6) clamp from the water bypass valve.
8. Remove the heater outlet pipe from the water bypass valve.
9. Using the J 38185, reposition the heater inlet hose clamp from the water bypass valve.
10. Remove the heater inlet hose from the water bypass valve.
11. Using the J 38185, reposition the heater outlet hose clamp from the water bypass valve.
12. Remove the heater outlet hose from the water bypass valve.
13. Remove the bolt (3) that retains the water bypass valve (4) to the heater assembly.
14. Remove the water bypass valve.

INSTALLATION PROCEDURE




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