Thermostat Repair Procedures

Removal

Removing the thermostat may cause negative consequences, resulting in reduced cooling efficiency. Do not remove the thermostat, even if the engine is prone to overheating.

1. 1
   Drain the engine coolant so that the level is below the thermostat. (Refer to Cooling System - "Coolant")
2. 2
   Disconnect the radiator lower hose (A).

   

   (Refer to Cooling System - "Radiator Hose")
3. 3
   Remove the water inlet connection (A) and the thermostat (B).

   

Inspection

1. 1
   Immerse the thermostat in water heated to above 95 °C, then heat for at least 3 minutes to check the valve lift.

   

   Do not use water below 95 °C. Do not heat the unit directly, as this will damage the thermostat.

2. 2
   Check the valve opening temperature. Valve opening temperature: 88±2°C (109.4±3.6°F). Full open temperature: 100°C (212°F). If the valve opening temperature does not meet the specification, replace the thermostat.
3. 3
   Check the valve lift.

   Valve lift: 10 mm (0.3937 in) or more at 95 °C

   If the valve lift is not as specified, replace the thermostat.

Installation

1. 1
   Place the thermostat into the thermostat housing.

   1. Install the thermostat with the jiggle valve facing up.
   2. Install a new thermostat (B).

      

2. 2
   Install the water inlet pipe (A).

   Tightening torque: 9.8 ~ 11.8 N·m

3. 3
   Connect the lower radiator hose (A).

   

4. 4
   Install the upper radiator hose. (Refer to Cooling System - "Radiator Hose")
5. 5
   Fill the engine coolant.
6. 6
   Start the engine and check for leaks.