Thermostat: Service and Repair

THERMOSTAT INLET HOUSING AND ELEMENT REPLACEMENT- L81

REMOVAL





1. Drain coolant.
2. Lift and support intake manifold.





3. Disconnect radiator hose from coolant pipe.
4. Remove coolant pipe/engine lift bracket bolt.
5. Rotate oil level indicator and tube away from pipe.





6. Remove thermostat extension pipe.
7. Remove and discard O-ring seals.





8. Remove thermostat with housing:
8.1. Remove bolts.
8.2. Tilt the rear of the thermostat housing upward.
8.3. Lift out the housing.
8.4. Remove and discard O-ring seal.

INSTALLATION

NOTICE: SUV thermostat housing is different from L-Series.





1. Install the thermostat with housing:
1.1. Install a new O-ring seal.
1.2. Position the thermostat with the housing.
1.3. Apply thread sealant PST 565 to bolt threads.
1.4. Install the housing bolts.
Torque:
Thermostat Housing Bolts - L81: 20 N.m (15 ft. lbs.)





2. Lubricate the coolant pipe O-rings with coolant.
3. Install O-rings on coolant pipe.





IMPORTANT: The correct stack up should be cylinder head, engine lift bracket, coolant extension housing, oil level indicator tube bracket and bolt.

4. Properly position engine lift bracket.
5. Install coolant pipe into thermostat housing.
6. Rotate oil level tube into position.
7. Install coolant pipe engine lift bracket bolt.
Torque:
Coolant Pipe Engine Lift Bracket Bolt - L81: 20 N.m (15 ft. lbs.)





8. Connect radiator hose to coolant pipe.
9. Install intake manifold.
10. Fill the cooling system.