THERMOSTAT REMOVAL


  1. REMOVE NO. 1 ENGINE UNDER COVER

  2. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A003TOE

      Separate the hose from the hose clamp.

    2. Separate the wire harness clamp from the inlet air cleaner assembly.

    3. Remove the 3 bolts and inlet air cleaner assembly.

  3. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003UU4

      Remove the 2 bolts, clamp and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  4. DRAIN COOLANT (for Engine)

    Note

    Do not remove the reservoir tank cap and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Remove the reservoir tank cap.

      A003UP5E01
      Text in Illustration
      *1 Reservoir Tank Cap *2 Radiator Drain Cock Plug
      *3 Air Release Valve (w/ Air Release Valve) - -

    2. Loosen the radiator drain cock plug and drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

  5. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. A003UC0E01
      Text in Illustration
      *1 No. 2 Radiator Hose
      *2 No. 3 Water By-pass Hose

      Disconnect the No. 2 radiator hose and No. 3 water by-pass hose.

      Note


      • Do not apply force to the water inlet with thermostat sub-assembly when disconnecting the No. 3 water by-pass hose.

      • Do not damage the water inlet with thermostat sub-assembly.

      Tech Tips

      When disconnecting the No. 3 water by-pass hose, pinch the hose clamp, rotate the hose and pull it straight off the pipe.

    2. A003RQW

      Remove the 2 nuts, bolt and water inlet with thermostat sub-assembly.

    3. A003RMH

      Remove the gasket from the water inlet with thermostat sub-assembly.