Page 156
REPAIR INSTRUCTIONS, PART 1
Thermostat Housing Removal
[215 NG]
1. Loosen the hose clamp and disconnect the
by-pass hose at the front of the thermostat
housing and remove the by-pass tube from
the engine (Figure 142). The radiator hose
and hose from the surge tank should already
have been removed when removing the
engine from the vehicle.
142
Figure 142 — Thermostat Housing Hose Connections
2. Remove the cab heater coolant return hose
from the thermostat housing (if applicable).
Also remove the optional fuel heater coolant
return hose from the thermostat housing (if
equipped). The cab heater and optional fuel
heater coolant return hoses were relocated
from the thermostat housing to the radiator
lower tube during mid-2004.
3. Loosen and remove the three mounting
capscrews from the thermostat housing.
4. Remove the thermostat housing assembly
(Figure 143).
143
Figure 143 — Thermostat Housing
5. Remove the thermostats from the housing.
Remove and discard the seals/O-rings.
6. Examine the surface of the thermostat
sleeves and the housing bore area. Using
crocus cloth, remove any surface nicks,
burrs, sharp edges and tool marks from the
sleeves and bore area to prevent premature
failure of the seals.
1. By-Pass Hose
2. Radiator Hose Port
3. Surge Tank Port
1. Thermostat Housing 2. Coolant Manifold
5-111.bk Page 156 Monday, July 10, 2006 2:26 PM
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