Thermostat: Service and Repair

THERMOSTAT (2ZZ-GE) (May, 2003)
REPLACEMENT
1. DRAIN COOLANT
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 3 bolts and nut, then remove the cylinder head cover No.2.





4. REMOVE WIRE HARNESS PROTECTOR
(a) Unfasten the 3 clips, then remove the wire harness protector.
(b) Disconnect the pressure sensor connector.
5. REMOVE AIR SWITCHING VALVE ASSY





6. SEPARATE SUCTION HOSE SUB-ASSY
(a) Remove the 2 nuts, then separate the suction hose.





7. REMOVE FAN AND GENERATOR V BELT
(a) Slowly turn the V-ribbed belt tensioner clockwise, then remove the V belt.
8. REMOVE GENERATOR BRACKET NO.1
9. REMOVE GENERATOR ASSY

10. REMOVE WATER INLET
11. REMOVE THERMOSTAT





12. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve upward as shown in the illustration.

13. INSTALL WATER INLET
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)
14. INSTALL GENERATOR ASSY
15. INSTALL GENERATOR BRACKET NO.1





16. INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 N-m (100 kgf-cm, 87 in.-lbf)
17. INSTALL AIR SWITCHING VALVE ASSY
18. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 N-m (71 kgf-cm, 62 in.-lbf)
19. ADD COOLANT
20. CHECK FOR ENGINE COOLANT LEAKS