Coolant Bypass Valve Replacement

Coolant Bypass Valve Replacement

Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure

1. Partially drain the engine coolant. Refer to Cooling System Draining and Filling.
2. Using the J 38185 slide the hose clamp (2) back on the coolant bypass inlet hose.
3. Disconnect the coolant bypass inlet hose (1).






4. Using the J 38185 slide the hose clamp back on the coolant bypass outlet hose.
5. Using the J 38185 slide the hose clamp (2) back on the coolant bypass outlet hose.






6. Disconnect the coolant bypass outlet hose.
7. Disconnect the vacuum hose (1).






8. Using the J 38185 slide the hose clamp (1) back on the coolant bypass hose.
9. Disconnect the coolant bypass hose.






10. Remove the bolt (1) that retains the valve to the coolant bypass valve assembly.
11. Remove the coolant bypass valve.

Installation Procedure

1. Install the heater hoses to the coolant bypass valve.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.






2. Install the coolant bypass valve bolt (1). Tighten the bolt to 6.5 Nm (58 lb in).
3. Position the coolant bypass hose (2) into the original position.






4. Using the J 38185 slide the hose clamp (1) back into the original position.






5. Install the outlet bypass hose to the coolant bypass valve.
6. Use the J 38185 to slide the hose clamp (2) into there original position.
7. Connect the vacuum hose (1).
8. Install the bypass inlet hose (1) to the coolant bypass valve.
9. Use the J 38185 to slide the hose clamp (2) into their original position.
10. Fill the cooling system. Refer to Cooling System Draining and Filling.