Thermostat: Service and Repair

1. Drain coolant from engine, then remove upper radiator hose from thermostat housing.
2. Remove three retaining bolts from housing, then remove housing and thermostat as an assembly.

Fig. 6 Thermostat Replacement:

3. Install thermostat into housing, ensuring that jiggle valve is in relation to housing.
4. Position gasket onto housing using bolts as holding device, then install housing assembly and retaining bolts. Tighten to 8-10 ft lb.
5. Install upper radiator hose, then fill coolant system as follows:
a. Add 50% coolant, then add water until radiator is full. Allow coolant level to settle, then add more coolant until radiator remain full.
b. Install radiator cap to first notch, connect battery cable and wire connector to thermo switch. Start engine and let idle until upper hose is warm, then carefully remove radiator cap and top off coolant level.
c. Install cap securely and fill reservoir to FULL COLD mark with proper concentrate. Add water to FULL HOT mark. Check for leaks.