Thermostat: Service and Repair

REMOVAL

1. Disconnect battery cables, then drain coolant level below water outlet connection.
2. Remove vent plug from water outlet connection, then loosen top radiator hose clamp at radiator.
3. Remove water outlet retaining bolts, lift clear of engine and remove thermostat. Do not pry housing off.

INSTALLATION

1. Clean water outlet and cylinder head mating surfaces. Ensure that outlet pocket and air vent passage are free from rust. Clean vent plug and gasket.
2. Place thermostat fully inserted so it will compress gasket and press into water outlet connection to secure. Position cater outlet connection to intake manifold with a new gasket and secure with retaining bolts.
3. Tighten bolts to specifications, position top radiator hose and tighten clamps. Ensure that drain cock is closed.
4. Fill cooling system with recommended coolant mixture. The vent plug must be removed before radiator fill or engine may not fill completely. Do not turn plastic cap under vent plug or the gasket may be damaged. Do not try to add coolant through vent plug hole. Install vent plug after filling radiator and before starting engine.
5. Connect battery cables, then start engine and check for leaks. Check coolant level and fill if necessary.