Haynes Manual Car Thermostat Replacement Instructions

Haynes Repair manual books give two basic ways for replacing an automotive thermostat. This is a result of the thermostat being placed in two basic locations. One location is on top of the engine, located on the intake manifold. The second, requiring more work, is located near the bottom of the engine, by the water pump. Both require basic automotive hand tools.

Instructions

Intake Manifold

1

Trace the top radiator hose from the radiator to the location where the hose connects to the engine. The metal cover the hose connects to is called the thermostat intake. The thermostat is inside of that metal cover. This the easiest way to locate the thermostat.

2

Remove the radiator hose from the thermostat housing by loosening the retaining clip that secures it. A metal band clamp with a cam screw requires a screwdriver for removal. A metal compression clamp requires pliers. To remove, squeeze the compression tabs together. With the clamp removed, pull the hose off of the thermostat intake.

3

Remove the bolts that secure the thermostat housing to the intake manifold. This may require a ratchet, socket and extension bar. This depends on the make and model of vehicle. However, in some cases a wrench will suffice. Pull the thermostat housing upward to expose the thermostat.

4

Remove the old gasket and/or O-Ring from the thermostat housing and replace with new ones.

5

Pull the thermostat out of the intake manifold and place the new one into the hole. The thermostat has a pin on one end. This pin sticks out of the intake manifold and does not get submerged into the intake.

6

Place the cover back onto the intake manifold and secure it into place with the bolts.

7

Reattach the radiator hose to the thermostat intake.

Bottom Mounted

8

Drive the vehicle onto a set of ramps and secure the parking brake.

9

Drain the radiator fluid into a drain pan.

10

Trace the top radiator hose from the radiator to the location where it connects to the water pump water inlet. The thermostat is inside the water inlet.

11

Remove the radiator hose by loosening the clamp. Pull the radiator hose off the water inlet.

12

Remove the water inlet from the water pump by removing the bolt that secures the inlet to the stud. Pull the water inlet off the water pump to expose the thermostat.

13

Pull the O-ring out of the water inlet and place a new one into the water inlet.

14

Remove the thermostat and thermostat gasket from the water pump.

15

Place the new thermostat into the water pump with the pin sticking out of the pump. Place the new thermostat gasket onto the thermostat.

16

Place the water inlet back onto the water pump and secure it with the nut.

17

Reattach the radiator hose.