Removal And Installation

THERMOSTAT

Removal and Installation


WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.

CAUTION:
Perform when the engine is cold.
NOTE:
When removing components such as hoses, or tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Drain engine coolant from the radiator. Changing Engine Coolant.
2.Remove the cooler hose (CVT only).
3.Disconnect radiator hose (lower) and remove water inlet.
4.Remove the thermostat. Discard the O-ring.

CAUTION:
Do not reuse O-ring.
5.Remove thermostat housing, if necessary.

INSPECTION AFTER REMOVAL

1.Check valve seating condition at room temperature. It should seat tightly.





2.Check valve operation.
- Place a thread (A) so that it is caught in the valve of the thermostat (1). Immerse fully in a container filled with water (B).
Heat while stirring.
- The valve opening temperature is the temperature at which the valve opens and falls from the thread.
- Continue heating. Check the full-open lift amount.
- After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.
- If the thermostat is out of specification, replace it.






INSTALLATION

Installation is in the reverse order of removal.
Thermostat





- Install thermostat with the whole circumference of the flange (A) fitting securely inside of the O-ring (1).





- Install thermostat (1) into the thermostat housing (2) with jiggle valve (A) facing upwards.

CAUTION:
Do not reuse O-ring.
Thermostat Housing
- Securely insert the rubber ring into the mating groove of thermostat housing and install it.
- Install the thermostat housing to the cylinder block without displacing the gasket from the gasket position.

CAUTION:
Do not reuse O-rings.

INSPECTION AFTER INSTALLATION

- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: