Never remove the pressure relief cap under any conditions while the engine is operating. Failure to follow these instructions could result in damage to the cooling system or engine and/or personal injury. To avoid having scalding hot coolant or steam blow out of the cooling system or reservoir, use extreme care when removing the pressure relief cap from a hot cooling system or reservoir. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly until pressure begins to release. Step back while the pressure is released from the cooling system. When certain all pressure has been released, remove the pressure cap (still with a cloth).
- Raise the vehicle on a hoist.
Remove the lower radiator air deflector.
- Partially drain the engine cooling system to a level below the thermostat.
- Slide the hose clamp out of the way and disconnect the lower radiator hose from the water inlet connection.
Disconnect the hose from the water inlet connection.
- Remove the two bolts.
Remove the inlet connection.
- Remove the O-ring seal and the water thermostat.
- Inspect the O-ring seal for damage and install a new O-ring seal if necessary.
- Install the thermostat in the water inlet connection.
- Install the inlet connection and secure with the two mounting bolts. Torque the bolts to 15-22 ft. lbs. (20-30 Nm).
- Attach the hose to the water inlet connection.
- Connect the lower radiator hose to the water inlet connection and secure with the hose clamp.
- Install the lower radiator air deflector. Tighten the retainers to 71-106 inch lbs. (8-12 Nm)
- Lower the vehicle.
- Properly fill the cooling system. Start the engine, check for leaks, proper operation and coolant level.
- Drain the cooling system to a level below the thermostat.
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. In addition, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
- Disconnect the upper radiator hose at the thermostat housing.
- Remove the two thermostat-housing retaining bolts and remove the thermostat housing.
- Remove the thermostat and O-ring seal. Inspect the O-ring for damage and replace, as necessary.
- Make sure all mating surfaces are clean.
- Install the thermostat, O-ring, and thermostat housing. Make sure the thermostat is positioned as shown in the figure.
- Install and alternately tighten the thermostat housing retaining bolts to 15-22 ft. lbs. (20-30 Nm). Connect the upper radiator hose.
- Fill the cooling system as described in Section 1. Check for leaks.