Hyundai Coupes/Sedans 1994-1998 Repair Guide

Thermostat

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Remove the upper radiator hose from the water outlet fitting....



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Fig. Fig. 2: ....loosen the water outlet fitting bolts....



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Fig. Fig. 3: ....and remove the water outlet fitting...



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Fig. Fig. 4: ....then remove the thermostat



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Fig. Fig. 5: Use a scraper to remove the old gasket material. Take care not to damage the aluminum intake manifold



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Fig. Fig. 6: The water outlet fitting bolts directly to the intake manifold-1.5L (VIN J), 2.0L (VIN P) and 3.0L (VIN T) Engines



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Fig. Fig. 7: The water outlet fitting bolts to the thermostat housing, which bolts to the cylinder head-1.5L (VIN E) and 1.5L (VIN K) Engines



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Fig. Fig. 8: The water outlet fitting bolts to the thermostat housing, which bolts to the cylinder head. The heater hoses also connect to the thermostat housing-1.6L (VIN F), 1.8L (VIN M) and 2.0L (VIN F) Engines

  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 electrical harness from the coolant sensor or thermo switch, as necessary.
  4.  
  5. Disconnect the upper radiator hose at the water outlet fitting.
  6.  
  7. Remove the water outlet fitting and gasket.
  8.  
  9. Remove the thermostat.
  10.  

To install:
  1. Clean the mating surfaces of the water outlet fitting and intake manifold thoroughly.
  2.  
  3. Install the thermostat with the spring facing downward.
  4.  

The jiggle valve in the thermostat should be on the manifold side.

  1. Install the housing using a new gasket. Tighten the housing bolts to 12-14 ft. lbs. (17-20 Nm).
  2.  
  3. Connect the electrical harness to the coolant sensor or thermo switch.
  4.  
  5. Refill the cooling system.
  6.  
  7. Start the engine and allow it to reach operating temperature. Check for leaks.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.
  10.