Note: A new thermostat O-ring may be required during installation - see text.
1. On the C-series engine, the thermostat is located at the end of the upper radiator hose (at the water pump) and is held in place by a hose clamp.
2. On D and E series engines, the thermostat is located in the cylinder head outlet pipe, on the left side of the engine (see illustration).
5.2. On E-series engines, the thermostat is located in the outlet pipe of the cylinder head (marked with an arrow).
3. On F-series engines, the thermostat is located in a housing bolted to the left side of the cylinder head, under the distributor cover. To improve access, remove the distributor cap and air cleaner or intake duct.
Removal
4. Partially drain the liquid from the cooling system (see Section 1), so that its level drops below the thermostat.
5. Where necessary, loosen the clamp and disconnect the hose from the thermostat cover (see illustration).
5.5 Loosen the clamp securing the hose to the thermostat cover - D series engine.
6. On C-series engines, remove the thermostat from the hose (see illustration).
5.6. Remove the thermostat from the upper hose - C series engine.
7. On D-series engines, remove the thermostat/housing cover assembly (they form an integral unit). Remove the O-ring.
8. On E and F series engines, loosen the cover and remove the thermostat, then remove the O-ring (see illustrations).
5.8a. Remove the thermostat - E series engine.
5.8b. Remove the thermostat - F series engine.
Checking the serviceability
9. To test the thermostat, hang the component on a piece of twine in a container of cold water and immerse the thermometer in the same container. Heat the water and determine the temperature at which the thermostat begins to open. Continue heating the water until the thermostat opens fully, then remove it from the water.
10. The temperature at which the thermostat should begin to open is indicated on the component itself. If it does not start to open at this temperature, does not open completely in boiling water, or does not close completely after being removed from the water, the thermostat needs to be replaced.
Installation
11. Perform installation in reverse order, paying attention to the following: (see illustration):
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5.11 Install a new O-ring onto the thermostat/housing cover assembly - D-series engine.
- Where present, replace the O-ring.
- On C-series engines, ensure the thermostat bypass hole fits into the groove on the end of the water pump hose.
- Finally, fill the cooling system (see Section 1).