Thermostat: Service and Repair

Engine Coolant Thermostat Replacement (LUW)

Removal Procedure

Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.


1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Drain the coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.





3. Disconnect the engine wiring harness connector (1) and retainers (2).





4. Remove the wiring harness bracket nut (3) and bracket (4).





5. Disconnect the thermostat heating element sensor (1) and remove the radiator inlet hose (2).





6. Remove the thermostat housing retaining bolts (1).

7. Remove the thermostat housing (2).





8. Remove the thermostat (1) and discard the seal (2).

Installation Procedure





1. Fit the thermostat (1) to the coolant distributor and use a NEW seal (2).





Caution:
Refer to Fastener Caution Fastener Caution.

2. Install the thermostat housing (2) and tighten the thermostat housing bolts (1) to 10 Nm (89 lb in).





3. Install the radiator inlet hose (2) and connect the thermostat heating element sensor (1).





4. Install the wiring harness bracket (4) and tighten the nut (3) to 10 Nm (89 lb in).





5. Connect the engine harness connector (1) and harness retainers (2) to the bracket.

6. Refill the engine cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

7. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

8. Start the engine and check for coolant leaks.