Thermostat

REMOVAL & INSTALLATION

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.

1. Drain the cooling system into a suitable container to a level below the intake manifold.
2. Disconnect the negative battery cable.
3. On some engines, disconnect the air intake duct and intake manifold hoses from the thermostat housing.
4. Loosen the hose clamp, and disconnect the upper radiator hose from the thermostat housing.
5. Remove the thermostat housing mounting bolts, then remove the housing and thermostat. Note the placement and direction of the thermostat for ease of installation.

   NOTE: If the housing is difficult to remove, tap it lightly with a plastic-faced hammer.

6. Installation is the reverse of removal. Secure the thermostat housing mounting bolts to 4–9 ft. lbs. (6–12 Nm).
7. For non-turbo models, install the thermostat with the jiggle valve facing down.
8. For turbocharged models, install the thermostat with the jiggle valve at the 12 o'clock position.
9. Refill and bleed the cooling system.
10. Start the engine and bleed the cooling system and check for leaks.

    Fig. 1: Loosen the radiator draincock . . .

    Fig. 2: . . . and drain the coolant into a suitable container

    Fig. 3: Loosen and remove the thermostat housing retainer bolts

    Fig. 4: Detach the housing to reveal the thermostat and gasket

    Fig. 5: Remove the thermostat and gasket assembly

    Fig. 6: Loosen the bleeder screw on top of the radiator to bleed air from the cooling system