Thermostat: Service and Repair

Fig. 70b Thermostat Replacement Procedure:

Fig. 71b Thermostat Installation Direction:

WARNING: Do not remove pressure cap while engine is hot or under pressure.
1. Drain coolant to level below thermostat housing.
2. On turbocharged models, remove air intake hoses one (1) and two (2).
3. On non-turbocharged models, remove air intake hose (3).
4. Remove lower radiator hose (4), three housing retaining bolts. housing (5), gasket (8) and thermostat (9).
5. Clean mating surfaces and close drain.
6. Reverse removal procedures to install.
7. Refer to picture above before installing thermostat.
8. Ensure that drain is closed, then refill coolant. Replace cap, start engine until warm. Check of leaks, then recheck coolant and fill if necessary.