THERMOSTAT REMOVAL


  1. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A003ZJQ

      Remove the 9 clips and radiator support opening cover (for 9 Clip Type).

    2. A003XV0

      Remove the 7 clips and radiator support opening cover (for 7 Clip Type).

  2. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A003VRO

      Separate the water hose from the hose clamp.

    2. A003VGC

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

    3. Remove the 2 bolts, 2 clips and inlet air cleaner assembly.

  3. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003ZA1

      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 reserve 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. A003Z8O

      Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the reserve tank cap and drain the coolant.

      A003ZHYE01
      Text in Illustration
      *1 Reserve Tank Cap *2 Radiator Drain Cock Plug

  5. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. A003WNBE01
      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. A003X31

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

    3. A003ZHC

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