Thermostat: Service and Repair
THERMOSTATREPLACEMENT
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
5. REMOVE AIR CLEANER INLET NO.2
6. REMOVE AIR CLEANER CASE
7. REMOVE AIR CLEANER BRACKET
8. REMOVE AIR CLEANER INLET NO.1
9. REMOVE STARTER ASSEMBLY (TMMWV MADE)
10. REMOVE WATER INLET PIPE (TMC MADE)
a. Remove the bolt and the water inlet pipe.
b. Remove the O-ring from the water inlet pipe.
11. REMOVE WATER INLET (TMC MADE)
a. Disconnect the wire harness clamp.
b. Remove the 3 nuts and the water inlet.
12. REMOVE WATER INLET (TMMWV MADE)
a. Disconnect the wire harness clamp.
b. Remove the bolt and 3 nuts, then remove the water inlet.
13. REMOVE THERMOSTAT
14. INSTALL THERMOSTAT
a. Install a new gasket to the thermostat.
b. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
HINT: The jiggle valve may be set within 15° of either side of the pre scribed position.
15. INSTALL WATER INLET (TMC MADE)
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
16. INSTALL WATER INLET PIPE (TMC MADE)
a. Install a new O-ring to the water inlet pipe.
b. Apply soapy water to the O-ring.
c. Connect the water inlet pipe to the water inlet.
d. Install the bolt which is used to fix the water inlet pipe to the cylinder head.
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
17. INSTALL WATER INLET (TMMWV MADE)
Torque:
Nut 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt 20 Nm (199 kgf-cm, 14 ft. lbs.)
18. INSTALL STARTER ASSEMBLY (TMMWV MADE)
19. INSTALL AIR CLEANER INLET NO.1
20. INSTALL AIR CLEANER BRACKET
21. INSTALL AIR CLEANER CASE
22. INSTALL AIR CLEANER INLET NO.2
23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
24. ADD ENGINE COOLANT
25. CHECK FOR ENGINE COOLANT LEAKS