Heater Return Pipe Assembly Replacement

Removal Procedure

Caution

Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Raise the vehicle.
2. Drain the cooling system. Refer to Engine Coolant Check and Replacement .




3. Remove the right front tire and wheel assembly.
4. Remove the right upper wheelhouse panel.




5. Remove the right wheelhouse side splash shield (left hand shown).





Important

Installation of the wood block prior to the upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.

6. Place a 25 mm x 25 mm x 51 mm (1 in x 1 in x 2 in) long block of wood (1) between the torque strut and cradle.





Caution

To prevent personal injury, do not stand under a heater core outlet when removing the hose because some coolant will leak out after the hose is removed.

7. Move the heater outlet clamp and hose from the heater core outlet pipe.
8. Lower the vehicle.




9. Remove the three engine mount to front cover nuts and two engine mount to midrail bracket nuts. Allow the powertrain to rest on the block of wood.
10. Remove the mount.




11. Raise the vehicle.
12. Remove the four bracket to midrail bolts from the engine side of the bracket and the three bracket to midrail bolts from the wheelhouse side of the bracket.
13. Remove the bracket.




14. Open the fuel vapor line clamps holding the heater return line.
15. Remove the fuel vapor line clip from the stud.
16. Lower the vehicle.




17. Remove the remaining clamp and clip from the midrail.
18. Remove the washer bottle bolt and move the washer bottle aside.
19. Remove the hoses from the coolant surge tank and the heater return pipe.




20. Remove the heater return pipe from the vehicle.

Installation Procedure

1. Transfer the hose clamp to the new return pipe.
2. Install the heater return pipe behind the engine and into position at the coolant recovery reservoir.
3. Raise the vehicle.
4. Position the pipe in front of the dash clamps and clips on the studs. Close all clamps.




5. Install the hose to the heater core outlet. Position the clamp at 6 o'clock.




6. Lower the vehicle.
7. Position the pipe in the mid-rail clamp and close.
8. Install the hoses and clamps to the bottle and pipe. Position the clamps at 3 o'clock.

Notice

Refer to Fastener Notice in Cautions and Notices.

9. Install the washer bottle and bolt.
Tighten

Tighten the washer bottle attachment bolts to 4 N·m (35 lb in).





10. Install the midrail bracket.
11. Raise the vehicle.
12. Hand start all the midrail bracket bolts.
13. Tighten and torque all of the bolts.
Tighten

Tighten the midrail bracket bolts to 30 N·m (22 lb ft).





14. Lower the vehicle.

Notice

To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.

15. Install the two engine mount to the midrail bracket nuts first.
16. Install the three engine mount to the engine front cover nuts.
17. Remove the block of wood from under the torque strut after the upper mount assembly is installed.
Tighten
• Tighten the engine mount to front cover nuts to 50 N·m (37 lb ft).
• Tighten the engine mount to midrail bracket nuts to 50 N·m (37 lb ft).




18. Raise the vehicle.
19. Install the upper wheelhouse panel.




20. Install the wheelhouse side splash shield (left hand shown).
21. Install the tire and wheel assembly.
Tighten

Tighten the wheel nuts to 140 N·m (103 lb ft).

22. Close the radiator drain valve and install the engine block drain.




23. Lower the vehicle.
24. Fill the cooling system and leak check. Refer to Engine Coolant Check and Replacement .
25. Install and tighten the coolant surge tank cap.