Repair Procedure C

REPAIR PROCEDURE C - REPLACE THE 20-MM SEALING BOLT BEHIND THE ALTERNATOR

1. Remove the drive belt:

^ Set a long-handled, box-end wrench on the drive belt auto-tensioner from above the engine.

^ Slowly turn the wrench in the direction shown, then remove the drive belt.

NOTE:
This is a hydraulic type auto-tensioner; you must turn the wrench slowly to avoid damaging the auto-tensioner.

2. Remove the alternator. Do not disconnect its electrical connections, or damage the wires:

^ Refer to page 4-44 of the service manual, or

^ Online, enter keyword ALT, and select Alternator Removal and Installation from the list.

3. Drain the engine coolant.

4. Remove the EGR pipe from the thermostat housing.

5. Remove the EGR pipe and thermostat housing from the cylinder head.

6. Disconnect the water pipe, then lower it so you can access the 20-mm sealing bolt.

7. Remove the original sealing bolt and its washer.

8. Clean the sealer out of the block threads by running a pick tool or a toothbrush along the threads.

NOTE:
Pull any material from the threads out of the engine block. Do not push it in.

9. Coat the sealing surface on the engine block with clean engine oil.

10. Install a new sealing bolt and washer. Torque the sealing bolt to 34 N.m (25 lb-ft).

11. Reinstall the parts in the reverse order of removal.

12. Refill the radiator, then bleed the cooling system.