Coolant Line/Hose: Service and Repair

REMOVAL
WITHOUT AIR CONDITIONING
1. Partially drain cooling system.
Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
2. Loosen both bypass hose clamps and position to the center of hose.





WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.





CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.

3. Remove hose from vehicle.

WITH AIR CONDITIONING





If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing the generator or A/C compressor from their mounting bracket is not necessary. Also, discharging the A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor.

WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH THE ENGINE OFF. REFER TO REFRIGERANT WARNINGS.

1. Disconnect negative battery cable from battery.
2. Partially drain cooling system. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
3. Remove engine cover.





4. Remove Powertrain Control Module (PCM) mounting bolts and remove PCM. Do not disconnect 60-way connector from PCM.
5. Remove upper radiator hose clamp at radiator. A special clamp tool must be used to remove the constant tension clamps. Remove hose at radiator.
6. Remove two-piece fan shroud.
7. Unplug wiring harness from A/C compressor.
8. Remove the air cleaner assembly and plastic air cleaner intake tube.
9. Remove accessory drive belt.
10. The drive belt idler pulley must be removed to gain access to one of the A/C compressor/generator bracket mounting bolts. Remove the idler pulley bolt and remove idler pulley.
11. Remove the engine oil dipstick tube mounting bolt at the side of the A/C-generator mounting bracket.
12. Disconnect throttle body control cables.





13. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring.
14. Remove bracket-to-intake manifold bolts (number 1 and 2).





15. Remove remaining bracket-to-engine bolts.
16. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position.
17. Loosen and position both hose clamps to the center of bypass hose. A special clamp tool must be used to remove the constant tension clamps. Remove hose from vehicle.

INSTALLATION
WITHOUT AIR CONDITIONING
1. Position bypass hose clamps to the center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Fill cooling system.
5. Start and warm the engine. Check for leaks.

WITH AIR CONDITIONING
1. Position bypass hose clamps to the center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2) to 54 Am (40 ft. lbs.) torque. Tighten bracket mounting bolts to 40 Nm (30 ft. lbs.) torque.
5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube.
7. Connect throttle body control cables.
8. Install oil dipstick mounting bolt.
9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque.





10. Install the accessory drive belt.

CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to Belt Schematics in the Engine Accessory Drive Belt section of this group for correct belt routing. The correct belt with the correct length must be used.

11. Install air cleaner assembly and plastic air intake tube.
12. Install fan shroud.
13. Install upper radiator hose to radiator.
14. Connect wiring harness to A/C compressor.
15. Fill cooling system.
16. Start and warm the engine. Check for leaks.
17. Install engine cover.