Diesel Data: Automotive Repair

Thermostat: Service and Repair

Thermostat Replacement

Removal
1. Drain the engine coolant.
2. Remove the air cleaner assembly.
3. Remove the radiator hoses.
4. Remove the harness holder (A), ground cable (B), harness clamps (C), water bypass hose (D) and engine J/C connector clamp (E).





5. Remove the thermostat housing (A), then remove the thermostat (B).





Installation
1. Remove old liquid gasket from the thermostat housing mating surfaces, bolts and bolt holes.
2. Apply a 1.5 mm wide bead of the liquid gasket on the water passage, P/N 08717-0004, 08718-0001, 08718-0002, 08718-0003, or 08718-0009, along the broken lines (A).

NOTE: Do not install components if too much time has passed after applying the liquid gasket. (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.





3. Install the rubber seal (A) on the thermostat (B), then install the thermostat with the pin (C) up.





4. Install the thermostat housing (D).
5. Install the harness holder (A), ground cable (B), harness clamps (C), water bypass hose (D) and engine J/C connector clamp (E).





6. Install the radiator hoses.
7. Install the air cleaner assembly.

NOTE: After assembly, wait at least 30 minutes before filling engine with coolant.