3
3.23
THERMOSTAT
THERMOSTAT REPLACEMENT
1. Drain coolant so the coolant level is below the
thermostat housing, see: Coolant Drain / Radiator
Service (Sportsman), page 3.13.
2. Remove the intake/plenum., page 3.25
3. Thoroughly clean the area around the thermostat,
fuel injectors, and throttle body.
4. Remove the retaining fasteners
i
that secure the
fuel rail to the throttle body.
5. Gently pry/pull up on the rail to remove the injector/
rail assembly from the injector ports.
6. Plug the injector ports with clean shop towels to
prevent debris from entering the clean side of the
intake.
7. Remove the fasteners
o
that retain the thermostat
housing, then the housing.
8. Replace the thermostat and seal.
9. Torque fasteners to specification.
TORQUE
Thermostat Housing Fastener
7 ft-lbs (10 Nm)
TORQUE
Fuel Rail Mounting Screws:
44 in. lbs (5 Nm)
TORQUE
Plenum to Throttle Body Fasteners:
7 ft-lbs (10 Nm)
10.Install of other removed components is reverse of
removal procedure.
11. Perform the “Cooling System Bleeding Procedure”.
Cooling System Bleeding Procedure, page 3.12
ENGINE / COOLING SYSTEM
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