Hyundai Coupes/Sedans 1986-1993 Repair Guide

Thermostat

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REMOVAL & INSTALLATION



1468cc Engine

See Figure 1 through 3

  1. Disconnect the negative battery cable. Remove the air cleaner.
  2.  



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Fig. Fig. 1: Thermostat assembly-1468cc and 2351cc engines



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Fig. Fig. 2: Thermostat assembly-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 3: Thermostat positioning on the 1468cc engine

  1. Drain the cooling system to a point below the level of the tubes in the top tank of the radiator.
  2.  
  3. Disconnect the hose at the thermostat water pipe.
  4.  
  5. Remove the water pipe support bracket nut.
  6.  
  7. Unbolt and remove the thermostat housing and pipe.
  8.  
  9. Lift out the thermostat. Discard the gasket.
  10.  

To install:
  1. Clean the mating surfaces of the housing and manifold thoroughly.
  2.  
  3. Install the thermostat with the spring facing downward and position a new gasket. The jiggle valve in the thermostat should be on the manifold side.
  4.  
  5. Install the housing and pipe assembly. Torque the housing bolts to 10 ft. lbs. (14 Nm); the intake manifold nut to 14 ft. lbs. (19 Nm).
  6.  
  7. Refill the cooling system. Connect the negative battery cable.
  8.  

1495cc, 1596cc, 1796cc and 1997cc Engines

See Figures 2, 3, 4 and 5



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Fig. Fig. 4: Thermostat assembly-1495cc engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the upper radiator hose from the thermostat housing.
  6.  
  7. Remove the thermostat housing and gasket.
  8.  
  9. Remove the thermostat, taking note of its original positioning in the housing.
  10.  

To install:
  1. Install the thermostat so its flange seats tightly in the machined groove in the thermostat case. Refer to its location prior to removal.
  2.  
  3. Use a new gasket and reinstall the thermostat housing. Torque the housing mounting bolts to 12-14 ft. lbs. (17-20 Nm).
  4.  
  5. Fill the system with coolant.
  6.  
  7. Connect the negative battery cable, run the vehicle until the thermostat opens and fill the radiator completely.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.
  10.  

2351cc Engine
  1. Connect the negative battery cable. Remove the air cleaner.
  2.  
  3. Drain the cooling system down well below the level of the tubes in the top tank of the radiator.
  4.  
  5. Disconnect the hose at the thermostat water pipe.
  6.  
  7. Unbolt and remove the thermostat housing.
  8.  
  9. Lift out the thermostat. Discard the gasket.
  10.  
  11. Clean the mating surfaces of the housing and manifold thoroughly.
  12.  

To install:
  1. Install the thermostat with the spring facing downward and position a new gasket.
  2.  
  3. Install the housing. Torque the housing bolts to 14 ft. lbs. (19 Nm).
  4.  
  5. Refill the cooling system. Connect the negative battery cable.
  6.  

2972cc Engine
  1. Disconnect the negative battery cable. Remove the air cleaner.
  2.  



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Fig. Fig. 5: Thermostat assembly-2972cc engine

  1. Drain the cooling system down well below the level of the tubes in the top tank of the radiator.
  2.  
  3. Disconnect the hose at the thermostat water pipe.
  4.  
  5. Unbolt and remove the thermostat housing.
  6.  
  7. Lift out the thermostat. Discard the gasket.
  8.  
  9. Clean the mating surfaces of the housing and manifold thoroughly.
  10.  

To install:
  1. Install the thermostat with the spring facing downward and position a new gasket.
  2.  
  3. Install the housing. Torque the housing bolts to 14 ft. lbs. (19 Nm).
  4.  
  5. Refill the cooling system. Connect the negative battery cable.
  6.  

 
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