Nothing quite as fun for a weekend upgrade as the thermostat. It's
cheap, It's easy, It's fun!... right.
There's 2 reasons to change this out, to lower coolant temps or
to replace a broken one. They are made by many companies, and come
in several varieties. Form stock temps, 180, and 160 degree. A lot
of people are using 160 with out a problem, but there is some speculation
that it can cause problems with the normal operation of the EGR
and IC pump. So I opted for the 180.
Step One: Removal
1)- Remove Air Box and intake crossover tube. Place a paper
towel in the orange elbow at the turbo to prevent from dropping
2)- Partially Drain the radiator enough to get the coolant out
of the upper radiator hose.
3)- Remove the Upper radiator hose. (2 clamps) one at the radiator,
and one at the front of the motor.
4)- Using a deep socket, remove the bolt on the front,driver
side corner of the thermostat housing
5)- Using a complex set up of an extension, wobble joint, and
short socket, you can get the the bolt in the rear passenger
6)- Remove the thermostat housing and thermostat.
1)- Prevent Overheating: There's 2 ways to do this, you can
drill a small hole in the thermostat to prevent an air pocket
from forming when you refill the coolant system, thus causing
the thermostat not to open. The other way is to make sure the
motor is fairly full of coolant. Mine, I could see coolant in
the cavity directly under the thermostat, this should sufficiently
heat the thermostat and cause it to open at the right time.
I haven't drilled a hole into any of the 3 I've changed, and
haven't had a problem with one of them overheating.
2)- Place thermostat back into it's place, and replace the thermostat
3)- Bolt the housing down, and reattach the upper radiator hose,
tightening the hose clamps sufficiently
4)- Refill the Coolant system.
Run the motor, keeping the overflow tank full. Make
sure the engine warms up completely. If it starts to overheat,
then the thermostat isn't opening, most likely due to trapped
air. You should notice that your engine temp gauge rests a little
lower when it's working properly. ;P
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