Thermostat: Service and Repair

REMOVAL

HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.

1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER INLET





3. DISCONNECT WATER INLET FROM WATER INLET HOUSING
Remove the 3 nuts, and disconnect the water inlet from the water inlet housing.
4. REMOVE THERMOSTAT
a. Remove the thermostat.
b. Remove the gasket from the thermostat.

INSPECTION
INSPECT THERMOSTAT





HINT: The thermostat is numbered with the valve opening temperature.





a. Immerse the thermostat in water and gradually heat the water.
b. Check the valve opening temperature.
Valve opening temperature: 80 - 84°C (176 - 183°F)
If the valve opening temperature is not as specified, replace the thermostat.





c. Check the valve lift.
Valve lift: 10 mm (0.39 inch) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET HOUSING
a. Install a new gasket to the thermostat.
b. Insert the thermostat into the water inlet housing with the jiggle valve facing straight upward.





HINT: The jiggle valve may be set within 30° of either side of the prescribed position.





2. INSTALL WATER INLET
Install the water inlet with the 3 nuts.
Torque: 19 Nm (195 kgf.cm, 14 ft. lbs.)
3. FILL WITH ENGINE COOLANT
4. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS
5. INSTALL AIR CLEANER INLET