Thermostat: Service and Repair

Removal Procedure

Notice: When adding coolant, use DEX-COOL� coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

1. Disconnect the negative battery cable.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Drain the coolant to a level below the thermostat. Recover the coolant.
3. Remove the air inlet to the throttle body.





4. Disconnect the surge tank inlet pipe from the thermostat housing.
5. If the coolant outlet is being replaced, disconnect the radiator inlet hose from the coolant outlet.





6. Remove the 2 bolts from the coolant outlet.
7. Remove the coolant outlet.





8. Remove the thermostat.
9. Clean the mating surfaces.

Installation Procedure





1. Install the thermostat.





2. Install the coolant outlet to the thermostat housing.
3. Install the coolant outlet bolts.

Tighten
Tighten the bolts to 25 Nm (18 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the radiator inlet hose to the coolant outlet, if the hose was removed.





5. Install the surge tank inlet pipe to the thermostat housing.
6. Install the air inlet to the throttle body.
7. Refill the coolant.
8. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 Nm (11 lb ft).

9. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.