Thermostat: Service and Repair

REMOVAL

WARNING: DO NOT REMOVE PRESSURE CAP OR ANY HOSE WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

1. Partially drain cooling system below thermostat level.
2. Disconnect hoses at coolant outlet connector.

Fig. 19 Coolant Outlet Connector - 2.0/2.4L:

3. Remove bolts attaching coolant outlet connector.
4. Remove coolant outlet connector and thermostat.

INSTALLATION
1. Clean sealing surfaces.

Fig. 21 Thermostat Indexing - 2.0/2.4L:

2. Place the new thermostat assembly into the coolant outlet connector. Align air bleed with notch on the coolant outlet connector.
3. Install coolant outlet connector onto thermostat housing and tighten bolts to 12.5 Nm (110 in. lbs.).
4. Connect hoses to coolant outlet connector.
5. Fill cooling system.