Water Passage Replacement
  1. Clean any dirt off the quick connector (A), the thermostat cover, and the lower radiator hose.
  1. Pull out the lock (B) by hand, then wiggle the quick connector loose, and remove it from the thermostat cover. Do not use any tools to remove the quick connector.
  1. Remove the connecting pipe mounting bolts (A) securing the connecting pipe (B).
  1. Remove the connecting pipe, the water bypass hose (C), and the positive crankcase ventilation (PCV) hose (D).
  1. Remove the water passage (A).
  1. Remove the thermostat housing (B).
  1. Install the thermostat housing (A) with a new O-ring (B).
  1. Clean and dry the water passage mating surfaces.
  1. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the engine block mating surface of the water passage and to the inner threads of the bolt holes.
    NOTE:
    • Apply liquid gasket about 3 mm (0.012 in.) diameter bead along the broken line (A).
    • Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove the old residue and reapply the liquid gasket.
  1. Install the water passage (A) with a new O-ring (B).
    NOTE:
    • Wait at least 30 minutes before filling the engine with coolant.
    • Do not run the engine for at least 3 hours after installing the water passage.
  1. Install the water bypass hose (A) and the PCV hose (B).
  1. Install the connecting pipe (C) with a new O-ring (D), then tighten the connecting pipe mounting bolts (E) securing the connecting pipe.
  1. Check the quick connector (A) and set ring (B) for cracks or damage. If the connector and/or set ring are cracked or damaged, replace the connector.
  1. Make sure the set ring is in place inside the quick connector. If the set ring is off the connector, replace the quick connector.
  1. Replace a new O-ring (C) in the quick connector.
  1. Check the lock (D). If the lock is damaged or deformed, replace it. When installing the new lock on the connector, push it straight down along the groove.
  1. Clean the connecting surface of the thermostat cover (E), then apply clean engine coolant around the connecting surface.
  1. Push the lock (A) down, then push the quick connector (B) onto the thermostat cover until you hear it click.