Toyota Camry 1983-1996 Repair Guide

Thermostat

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On both diesel and gasoline engines, the thermostat is located in the water inlet housing connected to the lower radiator hose.

REMOVAL & INSTALLATION




CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, 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.

Gasoline Engines

See Figures 1, 2, 3, 4, 5, 6 and 7

  1. Position a suitable drain pan under the radiator drain cock and drain the cooling system.
  2.  
  3. On the 1MZ-FE engine, remove the air cleaner cap assembly. Be sure to label all wiring disconnected.
  4.  
  5. Disconnect the water temperature switch harness from the water inlet housing (except 5S-FE engines).
  6.  
  7. Remove the oil filter on 5S-FE engines. On the 1MZ-FE engines, remove the heater hose covering the housing.
  8.  
  9. Loosen the hose clamp and disconnect the lower radiator hose from the water inlet housing.
  10.  
  11. Remove the two nuts from the water inlet housing and remove the housing from the water pump studs.
  12.  
  13. Remove the thermostat and rubber O-ring gasket from the water inlet housing.
  14.  

To install:
  1. Make sure all the gasket surfaces are clean. Clean the inside of the inlet housing and the radiator hose connection with a rag.
  2.  
  3. Install the new rubber O-ring gasket onto the thermostat. On 2SE and 3S-FE engines, align the jiggle valve of the thermostat with the protrusion on the water inlet housing. On 5S-FE engines, align the jiggle valve with the upper side of the stud bolt. On 2VZ-FE and 3VZ-FE engines, align the jiggle valve with the stud bolt. Insert the thermostat into the housing.
  4.  



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Fig. Fig. 1: Remove the thermostat housing from the engine with the coolant temperature sensor-1MZ-FE engine



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Fig. Fig. 2: Removing the thermostat from the engine-1MZ-FE engine



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Fig. Fig. 3: Always discard the old O-ring from the thermostat, if reusing the old component



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Fig. Fig. 4: Always replace the thermostat with the correct temperature specifications



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Fig. Fig. 5: The thermostat is placed in between the housing and the cylinder head as shown here-2S-ELC and 3S-FE engines



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Fig. Fig. 6: Line-up the jiggle valve with the protrusion on the housing-5S-FE engine

  1. Position the water inlet housing with the thermostat over the studs on the water pump and install the two nuts. Tighten the two nuts to 78 inch lbs. (9 Nm) on 4 cyl. engines, 2VZ-FE and 3VZ-FE; 14 ft. lbs. (20 Nm) and 69 inch lbs. (8 Nm) on 1MZ-FE engines.
  2.  



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Fig. Fig. 7: Thermostat installation-2VZ-FE and 3VZ-FE engines

Don't forget to install a new O-ring onto the water inlet pipe. Apply soapy water to the O-ring prior to installation.

  1. Connect the lower radiator hose to the inlet housing and install the hose clamp. On the 3VZ-FE, tighten the bolt holding the water inlet hose to the alternator belt adjusting bar to 14 ft. lbs. (20 Nm). On the 1MZ-FE engine, tighten the bolt retaining the water inlet pipe to the cylinder head to 14 ft. lbs. (20 Nm).
  2.  
  3. Attach the water temperature switch connector.
  4.  
  5. On the 1MZ-FE engines, install the heater hose removed.
  6.  
  7. Install the oil filter and check the oil level if removed. Install the air cleaner cap assembly on the 1MZ-FE engines.
  8.  
  9. Fill the cooling system with a good brand of ethylene glycol based coolant.
  10.  
  11. Start the engine and inspect for leaks.
  12.  

Diesel Engines
  1. Position a suitable drain pan under the radiator drain cock and drain the cooling system.
  2.  
  3. Disconnect the radiator cooling fan wiring.
  4.  
  5. Remove the right engine under cover. Unbolt and remove the radiator cooling fan shroud fan with motor.
  6.  
  7. Loosen the lower radiator hose from the water inlet housing.
  8.  
  9. Loosen the air conditioning compressor pulley lockbolt and drive belt adjusting bolt. Remove the drive belt from the pulley. Remove the three compressor mounting bolts and position the air conditioning compressor off to the side.
  10.  


CAUTION
DO NOT disconnect the refrigeration lines from the compressor.

  1. Remove the two bolts from the water inlet housing and remove the housing, rubber O-ring gasket and thermostat from the cylinder block.
  2.  

To install:
  1. Make sure all the inlet and cylinder block gasket surfaces are clean. Clean the inside of the inlet housing and the radiator hose connection with a rag.
  2.  
  3. Install the new rubber O-ring gasket onto the thermostat and place the thermostat into the cylinder block with the jiggle valve facing outward.
  4.  
  5. Place the water inlet with the thermostat and gasket onto the cylinder block and install the two bolts. Tighten the bolts to 65 inch lbs. (7 Nm).
  6.  
  7. Place the air conditioning compressor back into position and install the three mounting bolts. Install the drive belt onto the compressor pulley and adjust the drive belt tension.
  8.  
  9. Connect the lower radiator hose to the water inlet and install the hose clamp.
  10.  
  11. Install the radiator cooling fan shroud/fan/motor assembly. Install the right engine under cover.
  12.  
  13. Connect the radiator cooling fan motor harness.
  14.  
  15. Fill the cooling system with a good brand of ethylene glycol based coolant to the proper level.
  16.  
  17. Start the engine and inspect for leaks. Recheck the air conditioning compressor drive belt tension.
  18.  

 
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