Removal And Installation

THERMOSTAT

Removal and Installation


WARNING:
Do not remove the radiator cap when the engine is hot. Serious burns could occur from high-pressure engine coolant escaping from the radiator. Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.

REMOVAL

1.Drain engine coolant from radiator. Refer to "Draining Engine Coolant" Draining Engine Coolant.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on drive belt.
2.Remove air duct. Refer to "Removal and Installation" Removal And Installation.
3.Remove oil level gauge and guide. Refer to "Exploded View" Exploded View.
4.Disconnect radiator hose (lower) from water inlet. Refer to "Exploded View" Exploded View.
5.Remove water inlet, thermostat, and rubber ring.
NOTE:
Engine coolant will leak from cylinder block, so have a receptacle ready below.

INSPECTION AFTER REMOVAL

Thermostat





- Place a thread (A) so that it is caught in the valves of thermostat (1). Immerse fully in a container (B) filled with water. Heat while stirring.
- The valve opening temperature is the temperature at which the valve opens and falls from the thread.
- Continue heating. Check the full open valve lift amount.
- After checking the maximum valve lift amount, lower the water temperature and check the valve closing temperature.
Standard: Refer to "Standard and Limit" [1][2]Cooling System.
- If out of the standard specification range, replace the thermostat.

INSTALLATION

Installation is in the reverse order of removal.
Thermostat





- Install thermostat making sure rubber ring (1) groove fits securely to thermostat flange (A).

CAUTION:
Do not reuse rubber ring.





- Install thermostat (2) into the cylinder block (1) with jiggle valve (A)
facing upward.
Water Inlet





After installation, attach the water inlet clip (A) on the oil level gauge guide (1) positioned at location (B) as shown.

INSPECTION AFTER INSTALLATION

- Before starting engine, check oil/fluid levels, including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids, including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels, including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: