Thermostat Housing: Service and Repair

Thermostat Housing Removal and Installation

Removal

1. Drain the engine coolant Service and Repair.

2. Remove the air cleaner Service and Repair.

3. Remove the harness bracket (A), and cover the A/F sensor connector and disconnect the secondary HO2S connector with a tape to protect the connectors from engine coolant, then disconnect the lower radiator hose (B), the water bypass hoses (C), and the heater hose (D).






4. Remove the thermostat housing.






5. Remove the EGR plate (A), the thermostat cover (B), and the thermostat (C).






Installation

1. Install the new rubber seal (A) onto the thermostat (B), then install the thermostat with pin (C) up, and install the thermostat cover (D).





2. Install the EGR plate (E) with a new gasket (F).

3. Install the thermostat housing (A), using a new gasket (B) and new O-ring (C).






4. Connect the lower radiator hose (A), the heater hose (B), and the water bypass hoses (C), then install the harness bracket (D).





5. Install the air cleaner Service and Repair.

6. Refill the radiator with engine coolant, and bleed the air from the cooling system Service and Repair.

7. Clean up any spilled engine coolant.