Thermostat: Service and Repair
ENGINE COOLANT THERMOSTATIf the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type.
1. Disconnect the negative battery cable.
2. Drain the cooling system until the coolant level is below the thermostat
3. Air Conditioned vehicles: Remove the support bracket (generator mounting bracket-to-intake manifold) (2) located near the rear of the generator.
Note: On air conditioning equipped vehicles, the generator must be partially removed.
4. Remove the accessory drive belt.
5. Remove the generator mounting bolts. Do not remove any of the wiring at the generator. If equipped with 4WD, unplug the 4WD indicator lamp wiring harness (located near rear of generator).
6. Remove the generator. Position the generator to gain access for the thermostat gasket removal.
7. Remove the radiator upper hose clamp and upper hose at the thermostat housing.
8. Position the wiring harness (behind thermostat housing) to gain access to the thermostat housing.
9. Remove the thermostat housing mounting bolts, thermostat housing (1), gasket (2) and thermostat (3). Discard old gasket (3).
INSTALLATION
1. Clean the mating areas of the intake manifold and thermostat housing (1).
2. Install the thermostat (4) (spring side down) into the recessed machined groove on the intake manifold.
3. Install the gasket on the intake manifold and over the thermostat.
4. Position the thermostat housing (1) to the intake manifold. Note: The word FRONT stamped on housing. For adequate clearance, this must be placed towards the front of the vehicle. The housing is slightly angled forward after the installation to the intake manifold.
5. Install the housing-to-intake manifold bolts. Tighten the bolts to 23 Nm (200 in. lbs.)
6. Install the radiator upper hose to the thermostat housing.
7. Air Conditioned vehicles; Install the generator. Tighten the bolts to 41 Nm (30 ft. lbs.).
8. Install the support bracket (generator mounting bracket-to-intake manifold). Tighten the bolts to 54 Nm (40 ft. lbs.).
9. Install the accessory drive bel.
10. Fill the cooling system.
11. Connect battery negative cable.
12. Start and warm the engine. Check for leaks.