Thermostat Housing: Service and Repair

Engine Coolant Thermostat Housing Replacement (LUK)

Removal Procedure

1. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LFX) Service and RepairExhaust Front Pipe Replacement (LUK) Service and Repair.

2. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LUK) Service and Repair.

3. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.





4. Disconnect the power brake booster vacuum pipe (1).





5. Detach the power brake booster vacuum pipe retainers (1).





6. Disconnect the EVAP canister vacuum pipe connector (1).





7. Remove the drive motor generator battery high voltage cable retainers (1) and reposition the high voltage cable (2).

8. Remove the heater outlet bracket.

9. Disconnect the camshaft position sensor and reposition the engine harness.





10. Disconnect the following hoses:

* Heater coolant pump hose (1)

* Heater inlet hose (2)

* Radiator outlet hose (3)

* Surge tank hose (4)





11. Disconnect the engine coolant temperature sensor (1).

12. Remove the engine coolant thermostat housing fasteners (2).

13. Discard the thermostat housing seal (4).

14. Remove the engine coolant thermostat housing with the outlet pipe from the water pump.

Installation Procedure

1. Clean the sealing surface.

2. Install NEW seals to the water pump outlet pipe and thermostat housing inlet pipe.





3. Install the engine coolant thermostat housing (2) to the engine block with a NEW seal (4).

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the 3 fasteners (3) to the thermostat housing and tighten to 10 Nm (89 lb in).

5. Connect the electrical connector of the engine coolant temperature sensor (1).





6. Install the following hoses to the thermostat housing:

* Heater coolant pump hose (1)

* Heater inlet hose (2)

* Radiator outlet hose (3)

* Surge tank hose (4)





7. Attach the drive motor generator battery high voltage cable retainers (1) and reposition the high voltage cable (2).

8. Install the heater outlet bracket.

9. Connect the camshaft position sensor and reposition the engine harness.





10. Connect the power brake booster vacuum pipe (1).





11. Attach the power brake booster vacuum pipe retainers (1).





12. Connect the EVAP canister vacuum pipe connector (1).

13. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

14. Install the catalytic converter. Refer to Catalytic Converter Replacement (LUK) Service and Repair.

15. Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LFX) Service and RepairExhaust Front Pipe Replacement (LUK) Service and Repair.