Thermostat: Service and Repair

Removal Procedure

Caution: In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon.

1. Drain the engine coolant. Refer to Draining and Filling Cooling System.





2. Remove the three bolts (1) and position the A/C compressor aside.





3. Remove the radiator hose clamp (1) from the thermostat housing.





4. Remove the radiator hose from the thermostat housing.





5. Remove the three bolts and the thermostat housing (3).
6. Remove the thermostat and the O-ring from the thermostat housing.
7. Clean any corrosion or debris from the thermostat housing.
8. Clean the mating surfaces.
9. Inspect the thermostat. Refer to Thermostat Diagnosis.

Installation Procedure

Important: Position the air bleed valve so that it aligns with the mark on the cylinder head.

1. Install the thermostat in the described position to the cylinder head.
2. Install a new thermostat O-ring.





3. Install the thermostat housing (3).

Notice: Refer to Fastener Notice in Service Precautions.

4. Secure the thermostat housing (3) with three bolts.
^ Tighten the thermostat housing bolts to 16 Nm (12 ft. lbs.).





5. Install the A/C compressor and secure with three bolts (1).
^ Tighten the A/C compressor bolts to 23 Nm (17 ft lbs).





6. Install the radiator hose and clamp (1) to the thermostat housing.
7. Fill the radiator with approved coolant. Refer to Draining and Filling Cooling System.
8. Start the engine.
9. Allow the coolant to attain operating temperature (both hoses feel warm and the coolant is flowing through the radiator).
10. Check for leaks in the cooling system.
11. Shut off the engine.
12. Install the radiator cap.