Thermostat: Service and Repair

Removal Procedure





1. Drain the engine coolant. Refer to Draining and Filling Cooling System.
2. Remove the intake plenum. Refer to Intake Plenum Replacement.
3. Remove the intake manifold. Refer to Intake Manifold Replacement.
4. Remove the radiator inlet hose (1) from the thermostat outlet pipe.





5. Remove the thermostat outlet pipe bolt (1).
6. Remove the thermostat outlet pipe (2).





7. Remove the O-ring seals from the thermostat outlet pipe.
8. Discard the O-rings.





9. Remove the thermostat with the housing:
^ Remove the bolts (1).
^ Tilt the rear of the thermostat housing upward.
^ Lift out the housing (2).
^ Remove the seal ring.
^ Discard the seal ring.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.





1. Install the thermostat with the thermostat outlet housing (2):
^ Install a new seal ring.
^ Position the thermostat to the thermostat outlet housing.
^ Install the thermostat outlet housing bolts (1).
Tighten the thermostat outlet housing bolts to 20 Nm (15 ft. lbs.).





2. Lubricate two new O-rings with coolant.
3. Install the new O-rings in the thermostat outlet pipe.





4. Install the thermostat outlet pipe (2).
5. Install the thermostat outlet pipe bolt (1).
Tighten the thermostat outlet pipe bolt to 20 Nm (15 ft. lbs.).





6. Install the radiator inlet hose (1) to the thermostat outlet pipe.
7. Install the intake manifold. Refer to Intake Manifold Replacement.
8. Install the intake plenum. Refer to Intake Plenum Replacement.
9. Fill the cooling system. Refer to Draining and Filling Cooling System.