Thermostat: Service and Repair

THERMOSTAT

COMPONENTS:

REMOVAL
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

INSTALLATION

1. INSTALL THERMOSTAT
a. Install a new gasket to the thermostat.
b. Align the jiggle valve of the thermostat and water inlet, and insert the thermostat in the water inlet housing.

HINT: The jiggle valve should be set within 15° of either side of the prescribed position.

2. INSTALL WATER INLET
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
3. INSTALL WATER INLET PIPE
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.)
4. INSTALL WATER INLET
Torque:
Nut 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt 20 Nm (199 kgf-cm, 14 ft. lbs.)
5. INSTALL STARTER ASSEMBLY (TMMWV MADE)
6. INSTALL AIR CLEANER INLET NO. 1
7. INSTALL AIR CLEANER BRACKET
8. INSTALL AIR CLEANER CASE
9. INSTALL AIR CLEANER INLET NO. 2
10. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
11. ADD ENGINE COOLANT
12. CHECK FOR ENGINE COOLANT