Thermostat: Service and Repair

Engine Coolant Thermostat Replacement

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure




1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement (Service and Repair).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Vac-N-Fill) (Cooling System Draining and Filling (Vac-N-Fill)).
3. Using the J 38185, reposition the radiator outlet hose clamp (1) at the thermostat housing.
4. Remove the radiator outlet hose (2) from the thermostat housing.




5. Remove the thermostat housing bolts.




6. Remove the thermostat housing, thermostat, and gasket from the water pump housing.
7. Discard the old thermostat housing gasket.

Installation Procedure




1. Install a NEW thermostat housing gasket into the water pump housing.
2. Install the thermostat into the water pump housing.
3. Install the thermostat housing.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the thermostat housing bolts.

Tighten the bolts to 10 Nm (89 lb in).




5. Install the radiator outlet hose (2) to the thermostat housing.
6. Using the J 38185, position the radiator outlet hose clamp (1) at the thermostat housing.
7. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Vac-N-Fill) (Cooling System Draining and Filling (Vac-N-Fill)).
8. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (Service and Repair).