Thermostat: Service and Repair

REMOVAL

WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

1. Disconnect negative cable from battery.
2. Raise vehicle on hoist.
3. Drain cooling system.
4. Disconnect electrical connector from engine oil pressure switch.
5. Remove oil filter.
6. Cover the filter adaptor opening on the engine block to prevent residual coolant from entering engine lubrication system.
7. Disconnect lower radiator hose and heater hose from thermostat housing.





8. Remove thermostat housing bolts.
9. Remove housing, thermostat, and gasket.

INSTALLATION
1. Clean gasket sealing surfaces.

NOTE: Install thermostat with the bleed valve located at the 12 o'clock position.

2. Install thermostat and gasket into thermostat housing. For ease of installation, install bolts in housing for thermostat and gasket retention.
3. Install thermostat and housing to cylinder block. Tighten bolts to 12 Nm (105 inch lbs.).
4. Connect heater hose and lower radiator hose. Install hose clamps.
5. Install oil filter.
6. Connect electrical connector to engine oil pressure switch.
7. Lower vehicle and connect negative cable to battery.
8. Refill cooling system.
9. Check oil level and fill to proper level.
10. Run engine until proper engine temperature is reached, and cooling fan has cycled.