Thermostat Housing: Service and Repair

Engine Coolant Thermostat Housing Replacement (V8)

Removal Procedure

Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.


1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

Warning:
Refer to Radiator Cap Removal Warning Service Precautions.


2. Ensure engine is below cool before removing the coolant pressure cap.

3. Remove the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.


4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

5. Drain the coolant into a suitable container. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

6. Lower the vehicle.





Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.


7. Release the retaining hose clamp (2) and detach the hose (3) from the thermostat housing end (1).





8. Remove the thermostat housing (2) to water pump retaining bolts (1), and remove thermostat housing.

9. If the housing is to be replaced, discard the O-ring.

Installation Procedure

1. Install thermostat. Refer to Engine Coolant Thermostat Replacement (V8) Service and RepairEngine Coolant Thermostat Replacement (V6) Service and Repair.

2. Ensure all mating surfaces are thoroughly cleaned, using only a fine abrasive material.





Note:
Ensure a new O-ring seal is used.

3. Install the thermostat housing (2).

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the thermostat housing to water pump retaining bolts (1) and tighten to 14 Nm (124 lb in).





Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.


Caution:
Refer to Installing Hoses without Twists or Bends Caution Installing Hoses without Twists or Bends Caution.

5. Install the hose (3) to the thermostat housing (1), by opening the retaining hose clamp (2) and securing it over the hose.

6. Install the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

7. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

8. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

9. Inspect cooling system for leaks.

10. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).