Thermostat: Service and Repair

Thermostat Housing Crossover Replacement

Removal Procedure





1. Remove the air cleaner. Service and Repair
2. Drain the cooling system. Service and Repair
3. Disconnect the negative battery cables. Service and Repair
4. Remove the drive belt. Service and Repair
5. Disconnect the air conditioning (A/C) pressure switch electrical connector (1).
6. Disconnect the A/C compressor clutch electrical connector (2).
7. Remove the generator bracket. Service and Repair
8. Remove the front oil fill tube. Service and Repair





9. Disconnect the engine coolant temperature (ECT) sensor electrical connectors.
10. Remove the water outlet. Service and Repair
11. Without disconnecting the power steering hoses, remove the power steering pump bolts and the power steering pump. Reposition the power steering pump and secure to the side.
12. Remove the power steering pump bracket. Service and Repair Service and Repair





13. Remove the bolts and wiring harness bracket at the thermostat housing.
14. Position the bracket and wiring harness aside.
15. Remove the cooling fan pulley. Service and Repair





16. Reposition the turbocharger coolant return pipe hose clamp.
17. Remove the turbocharger coolant return pipe hose.





18. Remove the fuel line bracket bolt at the thermostat housing crossover.





19. Remove the water pump inlet pipe bolts.





20. Remove the thermostat housing crossover bolts and nuts.
21. Remove the thermostat housing crossover, with the bypass pipe.
22. Remove and discard the thermostat bypass pipe to water pump O-ring seal.
23. Remove and discard the thermostat housing crossover gaskets.
24. If necessary, perform the following:
24.1 Remove the thermostat bypass pipe from the thermostat housing crossover.
24.2 Remove and discard the thermostat bypass pipe O-ring seal.
24.3 Remove the thermostat cover bolts and cover.
24.4 Remove the thermostats.
24.5 Remove and discard the thermostat seals.
25. If required, clean and inspect the thermostat housing.

Installation Procedure





Notice: Refer to Fastener Notice.

1. If necessary, perform the following:
1.1 Install NEW seals to the thermostats.
1.2 Install the thermostats.
1.3 Install the thermostat cover and bolts.

Tighten
Tighten the bolts to 21 N.m (15 lb ft).

1.4 Install a NEW O-ring seal to the thermostat bypass pipe.
1.5 Install the thermostat bypass pipe to the thermostat housing.
2. Install a NEW thermostat bypass pipe to water pump O-ring seal.
3. Install the thermostat housing crossover using NEW gaskets.
4. Install the thermostat housing crossover bolts and nuts.

Tighten
Tighten the bolts/nuts to 21 N.m (15 lb ft).





5. Install the water pump inlet pipe bolts.

Tighten
Tighten the bolts to 21 N.m (15 lb ft).





6. Install the fuel line bracket bolt at the thermostat housing crossover.

Tighten
Tighten the bolt to 21 N.m (15 lb ft).






7. Install the turbocharger coolant return pipe hose.
8. Position the turbocharger coolant return pipe hose clamp.





9. Install the wiring harness bracket and bolts to the thermostat housing.

Tighten
Tighten the bolts to 10 N.m (89 lb in).

10. Install the cooling fan pulley. Service and Repair
11. Install the power steering pump bracket. Service and Repair
12. Reposition the power steering pump and install the power steering pump bolts.





13. Install the water outlet. Service and Repair
14. Connect the ECT sensor electrical connectors.
15. Install the front oil fill tube. Service and Repair
16. Install the generator bracket. Service and Repair





17. Connect the A/C compressor clutch electrical connector (2).
18. Connect the A/C cut out switch electrical connector (1).
19. Install the drive belt. Service and Repair
20. Connect the negative battery cables. Service and Repair
21. Fill the cooling system. Service and Repair
22. Install the air cleaner. Service and Repair