Thermostat: Service and Repair
ENGINE COOLANT THERMOSTATREMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES AND EYE WEAR.
NOTE: Inspect condition of all clamps and hoses, replace as necessary.
1. Disconnect negative battery cable.
2. Partially drain engine coolant.
3. Unplug connector, pull off locking element and pull out coolant temperature sensor.
4. Detach air intake hose at charge air distribution pipe.
5. Detach coolant hoses at thermostat housing.
6. Unscrew cap at oil filter housing.
7. Remove thermostat housing (Fig. 8).
8. Clean all sealing surfaces.
INSTALLATION
1. Clean all sealing surfaces.
2. Position and install thermostat housing with new gasket (Fig. 8). Tighten bolts to 9 Nm (80 inch lbs.).
NOTE: Inspect condition of all clamps and hoses, replace as necessary.
3. Install cap at oil filter housing.
4. Connect coolant hoses and vent hose (Fig. 8).
5. Attach air intake hose at charge air distribution pipe.
6. Close coolant drain.
7. Connect negative battery cable.
8. Fill coolant system to proper level with appropriate coolant mixture.
WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
9. Start engine and inspect for leaks.