Removal and Installation

THERMOSTAT AND WATER CONTROL VALVE


Removal and Installation


REMOVAL
1. Remove engine room cover (RH and LH). Component Removal and Installation.
2. Remove engine cover with power tool. Component.
3. Remove air duct (inlet). Component Removal and Installation.
4. Drain engine coolant from drain plugs on radiator and both side of cylinder block. Changing Engine Coolant and Disassembly and Assembly.

CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belts.
5. Disconnect water suction hose from water inlet.
6. Remove water inlet and thermostat.

CAUTION:
Never disassemble thermostat.
7. Remove intake manifolds (upper and lower). Component.
8. Disconnect radiator hose (upper) from thermostat housing.
9. Disconnect heater hoses from water outlet and heater pipe.
10. Remove thermostat housing, water outlet pipe, water connector, water control valve, water outlet, and heater pipe.

CAUTION:
Never disassemble water control valve.

INSPECTION AFTER REMOVAL
- Check that valves both in thermostat and water control valve are completely closing at normal temperature.





- Place a thread (A) so that it is caught in the valves of the thermostat (1) and water control valve. Immerse fully in a container (B) filled with water. Heat while stirring. (The example in the figure shows thermostat.)
- The valve opening temperature is the temperature at which the valve opens and falls from the thread.
- Continue heating. Check the maximum valve lift.

NOTE:
The maximum valve lift standard temperature for water control valve is the reference value.
- After checking the maximum valve lift, lower the water temperature and check the valve closing temperature.





- If the malfunctioning condition, when closing valve at normal temperature, or measured values are out of the standard, replace thermostat and/or water control valve.

INSTALLATION
Note the following, and install in the reverse order of removal.

CAUTION:
Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.

Thermostat and Water Control Valve





- Install thermostat and water control valve with the whole circumference of each flange (A) part fit securely inside rubber ring (1). (The example in the figure shows thermostat.)





- Install thermostat with jiggle valve facing upwards. (The position deviation may be within the range of �10 degrees)
- Install water control valve with the up-mark facing up and the frame center part facing upwards. (The position deviation may be within the range of �10 degrees)

Water Outlet Pipe and Heater Pipe
First apply a neutral detergent to O-rings, then quickly insert the insertion parts of the water outlet pipe and heater pipe into the installation holes.

INSPECTION AFTER INSTALLATION
- Check for leakage of engine coolant using radiator cap tester adapter (commercial service tool) and radiator cap tester (commercial service tool). Inspection.
- Start and warm up engine. Visually check if there is no leakage of engine coolant.