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 the cooling fan.
5. Remove the cooling fan belt.
^ Note the fitted position
^ Rotate the cooling fan tensioner clockwise
^ Loosen the cooling fan tensioner bolt to aid in removal of the belt
6. Remove the coolant hose support bracket.
^ Remove the 2 bolts.
^ Release the 2 coolant hoses.





7. Disconnect the coolant manifold to radiator hose.
^ Remove the clip.
8. Disconnect the thermostat housing to radiator hose.
^ Release the clip.
9. Disconnect the coolant manifold to coolant reservoir hose.
^ Release the clip.





10. Disconnect the coolant manifold bleed hose.
^ Release the clip.
11. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
12. Disconnect the cylinder block coolant hose.
^ Release the clip.





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.
^ Position the wiring harness bracket aside.
^ Remove and discard the 2 O-ring seals.





14. Disconnect the coolant manifold rear hose.
^ Rotate the coolant manifold.
^ Release the clip.





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. Install the coolant manifold.
^ Clean the components.
^ Install new O-ring seals.
^ Connect the rear hose and secure with the clip.
^ Connect the cylinder block hose and secure with the clip.
^ Attach the wiring harness bracket.
^ Tighten the Torx(R) screws to 10 Nm (7 ft. lbs).
4. Connect the remaining coolant hoses.
^ Secure with the clips.
5. Connect the ECT sensor electrical connector.
6. Install the coolant hose support bracket.
^ Tighten the bolts to 6 Nm (4 ft. lbs).
^ Secure the coolant hoses.
7. Install the cooling fan belt.
8. Install the cooling fan.
9. Connect the battery ground cable.
10. Refill and bleed the cooling system.