Thermostat: Service and Repair

THERMOSTAT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER INLET ASSEMBLY
3. REMOVE AIR CLEANER ASSEMBLY
4. REMOVE AIR CLEANER BRACKET
5. REMOVE AIR CLEANER INLET NO.1
6. REMOVE RADIATOR HOSE OUTLET
7. REMOVE WATER INLET PIPE
(a) Remove the bolt and inlet pipe.
8. REMOVE WATER INLET
(a) Remove the 3 bolts and water inlet.
9. REMOVE THERMOSTAT

INSPECTION
1. INSPECT THERMOSTAT

HINT: The thermostat is numbered with the valve opening temperature.





(a) Immerse the thermostat in water and gradually heat the water.





(b) Check the valve opening temperature.
Valve opening temperature: 80 to 84°C (176 to 183°F)
If the valve opening temperature is not as specified, replace the thermostat.





(c) Check the valve lift.
Valve lift: 10 mm (0.394 inch) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat is at low temperature (below 40°C (104°F)).
If not closed, replace the thermostat.

INSTALLATION





1. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

HINT: The jiggle valve may be set within 15° of either side of the prescribed position.

2. INSTALL WATER INLET
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
3. INSTALL WATER INLET PIPE
(a) Install a new O-ring to the inlet pipe.
(b) Apply soapy water to the O-ring.
(c) Connect the inlet pipe to the water inlet.
(d) Install the bolt holding the inlet pipe to the cylinder head.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
4. INSTALL AIR CLEANER ASSEMBLY
5. CONNECT VACUUM HOSES
6. ADD ENGINE COOLANT
7. CHECK FOR ENGINE COOLANT LEAKS