ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Thermostat

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REMOVAL & INSTALLATION



1.8L and 2.0L Engines

See Figure 1



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Fig. Fig. 1: Thermostat housing-1.8L and 2.0L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system. Disconnect the upper radiator hose from the thermostat housing.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner assembly.
  2.  
  3. Remove the thermostat housing from the intake manifold.
  4.  
  5. Remove the gasket and the thermostat.
  6.  

To install:
  1. Install the thermostat, with the spring facing the engine.
  2.  
  3. Using a new gasket, install the thermostat housing. Torque the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the radiator hose to the thermostat housing and refill the cooling system.
  6.  
  7. Install the air cleaner.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Operate the engine until normal operating temperatures are reached and check the thermostat operation.
  12.  

Diesel Engine

The thermostat is located under the thermostat housing, at the upper front of the engine.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the electrical connectors from the thermostat housing.
  2.  
  3. Remove the upper thermostat housing-to-lower housing bolts and the upper housing.
  4.  
  5. Remove the gasket and the thermostat.
  6.  
  7. Clean the gasket mounting surfaces.
  8.  

To install:
  1. Install the thermostat, with the spring facing the engine.
  2.  
  3. Using a new gasket, install the upper thermostat housing and torque the upper housing-to-lower housing bolts to 10-17 ft. lbs. (14-24 Nm).
  4.  
  5. Connect the electrical connectors.
  6.  
  7. Connect the radiator hose to the thermostat housing and refill the cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Operate the engine until normal operating temperatures are reached and check the thermostat operation.
  12.  

2.2L Gasoline Engine

See Figure 2



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Fig. Fig. 2: Thermostat housing-2.2L gasoline engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the electrical connectors from the thermostat housing.
  2.  
  3. Remove the upper thermostat housing-to-lower housing bolts and the upper housing.
  4.  
  5. Remove the gasket and the thermostat.
  6.  
  7. Clean the gasket mounting surfaces.
  8.  

To install:
  1. Install the thermostat, with the spring facing the engine.
  2.  
  3. Using a new gasket, install the upper thermostat housing and torque the upper housing-to-lower housing bolts to 89 inch lbs. lbs. (10 Nm).
  4.  
  5. Connect the electrical connectors.
  6.  
  7. Connect the radiator hose to the thermostat housing and refill the cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Operate the engine until normal operating temperatures are reached and check the thermostat operation.
  12.  

2.3L and 2.6L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a sealable container. Reuse the coolant if it isn't old or contaminated.
  4.  
  5. Disconnect the upper radiator hose from the thermostat housing on the intake manifold.
  6.  
  7. Unbolt and remove the thermostat housing.
  8.  
  9. Remove the thermostat and its gasket.
  10.  

To install:
  1. Clean the sealing surface thoroughly.
  2.  
  3. Install the thermostat and a new gasket. The thermostat's pin faces outward. Tighten the thermostat housing mounting bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Connect the upper radiator hose to the thermostat housing.
  6.  
  7. Refill and bleed the cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Warm the engine up to normal operating temperature and test the operation of the thermostat. Check for coolant leaks.
  12.  

2.8L and 3.1L Engines

See Figures 3, 4, 5 and 6



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Fig. Fig. 3: Thermostat housing-2.8L and 3.1L engines



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Fig. Fig. 4: Removing the thermostat housing bolts-2.8L engine



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Fig. Fig. 5: Place the hose and housing aside to gain access to the thermostat-2.8L engine



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Fig. Fig. 6: When installing the thermostat the spring side must be in the block-2.8L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a clean container so it can be reused.
  4.  
  5. Remove the upper radiator hose from the thermostat housing.
  6.  
  7. Remove the thermostat housing mounting bolts and remove the thermostat.
  8.  

To install:
  1. Clean the sealing surface, use a new gasket and install the thermostat with the spring toward the engine. Torque the thermostat housing mounting bolts to 18 ft. lbs. (24 Nm).
  2.  
  3. Connect the radiator hose to the thermostat housing.
  4.  
  5. Refill the cooling system and connect the negative battery cable.
  6.  
  7. Start the engine and add coolant as needed until the level stabilizes below the radiator cap.
  8.  
  9. Install the radiator cap and check for leaks.
  10.  

3.2L Engine

See Figure 7



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Fig. Fig. 7: Thermostat housing-3.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a clean container so it can be reused.
  4.  
  5. Disconnect the upper radiator hose from the thermostat housing.
  6.  
  7. Unbolt and remove the thermostat housing. Remove the thermostat and its gasket.
  8.  

To install:
  1. Clean the sealing surface. Use a new gasket and install the thermostat with the spring toward the engine. Torque the thermostat housing mounting bolts to 14 ft. lbs. (19 Nm).
  2.  
  3. Connect the radiator hose to the thermostat housing.
  4.  
  5. Refill and bleed the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and add coolant as needed until the level stabilizes below the radiator cap.
  10.  
  11. Install the radiator cap and check for leaks.
  12.  

 
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