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    2007 Suzuki Aerio FWD 2.3L MFI DOHC 4cyl

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    Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

    Removal & Installation

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    4.0L Engine



    1. Drain the cooling system.
    2.  
    3. Disconnect the upper radiator hose from the thermostat housing.
    4.  
    5. Remove the thermostat housing and the thermostat.
    6.  
    7. Installation is the reverse of the removal procedure.
    8.  
    9. Install a new O-ring seal in the thermostat housing.
    10.  
    11. Torque the thermostat housing bolts to 89 inch lbs. (10 Nm).
    12.  
    13. Fill and bleed the cooling system.
    14.  

    1. Drain the cooling system.
    2.  
    3. Remove the air cleaner outlet tube.
    4.  
    5. Remove the wiring from the alternator and position the harness aside.
    6.  
    7. Disconnect the upper radiator hose from the thermostat housing.
    8.  
    9. Remove the thermostat housing and the thermostat.
    10.  
    11. Installation is the reverse of the removal procedure.
    12.  
    13. Install a new O-ring seal in the thermostat housing.
    14.  
    15. Fill and bleed the cooling system.
    16.  

    4.6L Engine



    1. Drain the cooling system.
      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.

    2.  
    3. Remove the bolts and position the thermostat housing cover out of the way.
    4.  
    5. Remove the O-ring seal and the thermostat.
    6.  

    To install:

    1. Install the thermostat with the spring facing down.
      NOTE
      Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal, if necessary.

    2.  
    3. Position the thermostat housing cover, install bolts and tighten to 18 ft. lbs (25 Nm).
    4.  
    5. Fill and bleed the cooling system.
    6.  

    1. Position the vehicle on a hoist.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the oil filter drip shield.
    6.  
    7. Remove the coolant inlet connector.
    8.  
    9. Remove the thermostat.
    10.  
    11. Installation is the reverse of the removal procedure.
    12.  
    13. Tighten the coolant inlet connector bolts to 89 inch lbs. (10 Nm).
    14.  
    15. Fill and bleed the cooling system.
    16.  

    1. Drain the cooling system.
    2.  
    3. Remove the bolts and position the thermostat housing out of the way.
    4.  
    5. Remove the thermostat and gasket.
    6.  
    7. Installation is the reverse of the removal procedure.
    8.  
    9. Install a new O-ring seal in the thermostat housing.
    10.  
    11. Torque the thermostat housing bolts to 18 ft. lbs. (25 Nm).
    12.  
    13. Fill and bleed the cooling system.
    14.  

    5.0L Engines



    1. Drain the cooling system.
      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.

    2.  
    3. Disconnect the battery ground.
    4.  
    5. Remove the upper radiator hose.

      Click image to see an enlarged view

      Fig. Exploded view of the 5.0L engine thermostat and related components

    6.  
    7. Remove the 2 thermostat housing attaching bolts.
    8.  
    9. Loosen the bypass hose at the water pump.
    10.  
    11. Remove the thermostat housing. You may have to tap it loose with a plastic mallet or your hand.
    12.  

    To install:


    WARNING
    Do not use a sharp metal tool for scraping. Damage to the sealing surfaces could result and cause a leak.



    Click image to see an enlarged view

    Fig. Align the air bleed hole on the thermostat with the notch in the housing, which is also the 12 o-clock position

    1. Clean all mating surfaces thoroughly.
    2.  
    3. Position the thermostat in the housing making sure that the air release valve is in the up (12 o'clock) position.
    4.  
    5. Coat the mating surfaces of the housing and engine with an adhesive type sealer. Position the new gasket on the engine and place the housing on the engine. Tighten the bolts to 12-18 ft. lbs. (16-24 Nm).
    6.  

     
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