Thermostat

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.
2. Drain the cooling system.

   CAUTION
   Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

3. Remove any necessary components to access the thermostat.
4. Remove the thermostat housing retaining bolts.
5. Lift the housing from the engine.
6. Remove the thermostat taking note of its original position in the housing.

   To install:

   NOTE: In order to prevent leakage, make sure both mating surfaces are clean and free of any old gasket material.

7. Install the thermostat so its flange seats tightly in the machined groove in the intake manifold or thermostat case. Refer to its location prior to removal. Align the relief valve with the alignment mark on the thermostat housing.
8. Use a new gasket or O-ring and reinstall the thermostat housing. Torque the housing mounting bolts to the following specifications:
   • 1.8L engine: 16 ft. lbs. (22 Nm)
   • 1.5L, 1.6L, 2.0L DOHC, and 1990–92 2.0L SOHC engines: 12–14 ft. lbs. (17–20 Nm)
   • 1993 2.0L SOHC engine: 7–10 ft. lbs. (10–15 Nm)
   • 2.4L engine: 10 ft. lbs. (14 Nm)
   • 3.0L and 3.5L engines: 12–14 ft. lbs. (17–20 Nm)
9. Fill the system with coolant.
10. Install the removed air intake plumbing.
11. Connect the negative battery cable, run the vehicle until the thermostat opens and fill the radiator completely.
12. Once the vehicle has cooled, recheck the coolant level.