Engine Coolant Thermostat Housing Replacement (LEA or LUK)

Engine Coolant Thermostat Housing Replacement (LEA or LUK)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Remove the transmission rear mount. Refer to Transmission Rear Mount Replacement Transmission Rear Mount Replacement.





3. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.

Note:
A drain has been provided at the bottom of the water pump for engine block coolant drainage.





4. Remove the following hoses from the thermostat housing (6) :

* Radiator Outlet Hose (1).

* Surge Tank Hose (2).

* Heater Outlet Hose (3).

* Heater Inlet Hose (4).

5. Disconnect the Engine Coolant Temperature (ECT) sensor (5).





6. Remove the thermostat housing fasteners (1).

Note:
Twist the water transfer pipe while pulling in order to remove it from the water pump.

7. Remove the thermostat housing (2) from the vehicle.

8. Remove the water transfer pipe (5) from the thermostat housing, if necessary.

9. Remove and discard the water transfer pipe O-ring seals (4) and the thermostat housing seal (3).





10. Remove the thermostat cover fasteners (1) and cover (2), if necessary.

11. Remove the thermostat (3), if necessary.

12. Remove and discard the thermostat cover O-ring seal, if necessary.

13. Remove all debris and thread sealant from the engine coolant temperature (ECT) sensor and bolt holes if the housing is being re-used.

Installation Procedure

1. If installing a NEW thermostat housing transfer the thermostat ,water inlet and the ECT sensor.





2. Install a NEW thermostat cover O-ring seal into the recess groove.

3. Install the thermostat (3), if necessary.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the thermostat cover fasteners (1), if necessary and tighten to 10 Nm (89 lb in).

5. Install a NEW thermostat housing to engine gasket onto the thermostat housing.

6. Load the thermostat housing assembly into position.





Note:
The water feed pipe seals can be lightly lubricated with coolant to aid during installation.

7. Install NEW O-ring seals (4) onto the water feed pipe (5).

Note:
Lubricate the O-rings with coolant ONLY.

8. Install the water feed pipe (5) into the thermostat housing aligning locator tab.

9. Align the water pipe (5) to water pump.

10. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.

11. Position the thermostat housing (2) against the engine with a NEW seal (3).

12. Install the thermostat housing fasteners (1) and tighten to 10 Nm (89 lb in).

13. Install the ECT sensor, if necessary and tighten to 20 Nm (15 lb ft).





14. Install the following hoses from the thermostat housing (6) :

* Radiator Outlet Hose (1).

* Surge Tank Hose (2).

* Heater Outlet Hose (3).

* Heater Inlet Hose (4).

15. Connect the Engine Coolant Temperature (ECT) sensor (5).





16. Verify the drain valves at the radiator and water pump are closed.

17. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).