Thermostat: Service and Repair

Thermostat:

REMOVAL
1. Remove negative battery cable.
2. Drain the radiator to below the level of the thermostat.
3. Remove air cleaner if required.
4. Remove intake duct.
5. Remove throttle body.
6. Remove plenum.

WARNING: To reduce the risk of fire and personal injury, always relieve fuel system pressure prior to disconnecting fuel system components.

7. Remove fuel pipes and brackets. Refer to Fuel System Pressure Relief Procedure for fuel pressure bleed procedure.
8. Remove radiator inlet hose and clamp.
9. Remove thermostat housing bolts.
10. Remove thermostat housing and thermostat.
11. Remove gasket, if not attached to thermostat.

NOTE: Clean gasket surfaces on the intake manifold and thermostat housing.

INSTALLATION
1. Install new gasket, if not attached to thermostat.
2. Install thermostat and thermostat housing.
3. Install thermostat housing bolts and torque to 25 Nm (18 ft. lbs. ).
5. Install radiator inlet hose and clamp.
6. Install fuel pipes and brackets. Torque fuel pipes to 27 Nm ( 20 ft. lb. ).
7. Install plenum and torque bolts/studs to 25 Nm ( 18 lb.ft ).
8. Install throttle body attaching bolts and torque to 27 Nm (20 lb.ft).
9. Install intake duct.
10. Install air cleaner, if required.
11. Connect negative battery cable and torque bolts to 15 Nm ( 11 ft.lb. ). Refer to Idle Learn Procedure.
12. Refill the radiator.