INSTALLATION
GAS - PRIMARY THERMOSTAT
1. Position thermostat into the water plenum, aligning air bleed with the location notch on inlet housing (2).
2. Install inlet housing (2) onto coolant adapter. Tighten bolts to 9 N·m (79 in. lbs.).
3. Connect coolant hose (1).
4. Install air filter housing.
5. Fill cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
GAS - SECONDARY THERMOSTAT
1. Position thermostat into the cylinder head.
2. Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter. Replace O-ring as necessary.
3. Lubricate O-rings with soapy water.
4. Position coolant adapter on water pump inlet tube and cylinder head.
5. Install coolant adapter mounting bolts. Tighten bolts to 18.1 N·m (159 in. lbs.).
6. Connect front coolant hose (1).
7. Connect two rear coolant hoses (1).
8. Connect radiator hose (3).
9. Install air filter housing.
10. Fill cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
DIESEL ENGINE
1. Clean all sealing surfaces.
2. Position and install thermostat housing (2). Tighten bolts to 9N·m (80 lbs.in.).
NOTE: Inspect condition of all clamps and hoses, replace as necessary.
3. Connect coolant temperature sensor electrical connector.
4. Install generator (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
5. Install engine cover (Refer to 9 - ENGINE - INSTALLATION).
6. Connect negative battery cable.
7. Fill coolant system to proper level with appropriate coolant mixture (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
8. Start engine and inspect for leaks.