Thermostat Housing: Service and Repair

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the battery negative cable. Refer to Battery Cable Replacement (Battery Disconnect/Connect) in Starting and Charging.





2. Disconnect the battery negative cable from the auxiliary battery terminal. Refer to Battery Cable Replacement (Battery Cable Aux Negative) in Starting and Charging.
3. Drain the coolant from the radiator.





4. Remove the air cleaner assembly from the vehicle.





5. Remove the air intake duct from the turbocharger.
6. Remove the nut securing the dipstick tubes at the thermostat housing.
7. Remove the stud securing the fuel bleed valve at the thermostat housing.
8. Remove the A/C compressor.
9. Disconnect the coolant temperature sensor electrical connector.
10. Disconnect the heater hose at the thermostat housing crossover.





11. Disconnect the by-pass hose at the thermostat housing crossover.





12. Disconnect the upper radiator hose at the thermostat housing crossover.





13. Remove the studs and bolts securing the thermostat housing crossover to the engine.
14. Remove the thermostat housing crossover.
15. Clean the thermostat housing crossover sealing surfaces.

Installation Procedure





1. Install the new gaskets.
2. Install the thermostat housing crossover.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the studs and bolts retaining the thermostat housing crossover to the engine.
^ Tighten the bolts and studs to 47 Nm (35 ft. lbs.).





4. Connect the upper radiator hose to the thermostat housing crossover.





5. Connect the by-pass hose to the thermostat housing crossover.
6. Connect the heater hose to the thermostat housing crossover.
7. Connect the electrical connector to the coolant temperature sensor.
8. Install the A/C compressor.
9. Install the stud in order to secure the fuel bleed valve at the thermostat housing.
10. Install the nut in order to secure the dipstick tubes at the thermostat housing.





11. Connect the battery negative cable to the auxiliary battery terminal.





12. Connect the battery negative cable to the battery terminal.
13. Refill the engine cooling system.
14. Bleed the air from the engine cooling system by the following:
14.1. Remove the cap from the surge tank.
14.2. Remove the bleed screw (slotted) from the top of the thermostat housing.
14.3. Pour anti-freeze into the surge tank, and watch for a of anti-freeze from the bleed screw.
14.4. When a constant flow of anti-freeze is reached, closed the bleed screw at the top of the thermostat housing.
14.5. Continue to fill the surge tank to the proper level.
14.6. Install the cap on the surge tank.





15. Install the air intake duct to the turbocharger.





16. Install the air cleaner assembly in the vehicle.
17. Inspect the system for coolant leaks.