Water Outlet Replacement LH2

Special Tools

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.



4. Remove the throttle body from the water outlet housing. Refer to Throttle Body Assembly Replacement.
5. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
6. Remove the purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.
7. Position the J 38185 to the hose clamps to remove the following hoses from the water outlet housing:

•	The surge tank outlet hose

•	The radiator hose

•	The heater hose

•	The bypass hose




8. Remove the bolts securing the water outlet housing to the cylinder heads. Discard the gasket.
9. Clean and inspect. Refer to Water Outlet Housing Cleaning and Inspection.
10. Remove the following components from the water outlet housing:

•	The water crossover pipe plug

•	The throttle body inlet heater hose fitting

1. Install a new water outlet housing gasket.

Caution: Refer to Fastener Caution in the Preface section.

2. Place the water outlet housing in position and hand start the bolts to hold the housing in place.
3. Tighten the water outlet housing bolts and tighten to 25 N·m (18 lb ft).
4. Connect the following hoses to the water outlet housing:

•	The bypass hose

•	The heater hose

•	The radiator hose

•	The surge tank inlet hose

5. Position the J 38185 to the hose clamps to secure the hoses to the water outlet housing.
6. Install the purge solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.



7. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
8. Install the throttle body to the water outlet housing. Refer to Throttle Body Assembly Replacement.
9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
11. Fill the cooling system. Refer to Cooling System Draining and Filling.

Water Outlet Replacement LC3

1. Drain the engine cooling system. Refer to Cooling System Draining and Filling.
2. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.
3. Remove the supercharger assembly. Refer to Supercharger Replacement.
4. Remove the supercharger belt tensioner. Refer to Supercharger Belt Tensioner Replacement.
5. Remove the supercharger idler pulley. Refer to Belt Idler Pulley Replacement - Supercharger.



6. Remove the two coolant hoses from the water outlet housing. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement.
7. Remove the radiator hose from the water outlet housing. Refer to Radiator Inlet Hose Replacement.
8. Reposition the lower clamp on the bypass hose (1) as shown.



9. Remove the bolts securing the water outlet housing to the cylinder heads.
10. Remove the water outlet housing along with the bypass hose from the engine.
11. Discard the water outlet housing gaskets.
12. Disassemble the water outlet housing if necessary. Refer to Water Outlet Housing Disassemble
13. Clean and inspect the water outlet housing. Refer to Water Outlet Housing Cleaning and Inspection.

1. Assemble the water outlet housing if necessary. Refer to Water Outlet Housing Assemble.
2. Install NEW water outlet housing gaskets.
3. Install the water outlet housing with bypass hose to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the water outlet housing bolts and tighten to 25 N·m (18 lb ft).
5. Install the bypass hose clamp in the proper position.
6. Install the radiator hose to the water outlet housing. Refer to Radiator Inlet Hose Replacement.
7. Install the two coolant hoses to the water outlet housing. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement.



8. Install the supercharger idler pulley. Refer to Belt Idler Pulley Replacement - Supercharger.
9. Install the supercharger belt tensioner. Refer to Supercharger Belt Tensioner Replacement.
10. Install the supercharger assembly. Refer to Supercharger Replacement.
11. Fill the charge air cooling system with coolant. Refer to Charge Air Cooling System Draining and Filling.
12. Fill the engine cooling system with coolant. Refer to Cooling System Draining and Filling.
13. Check the engine cooling system for leaks.
14. Check the charge air cooling system for leaks.