Removal
Place the vehicle on a two-post lift, apply the parking brake, turn off the ignition and disconnect the ground wire from the battery.
Remove the engine crankcase guard.
Drain the fluid from the engine cooling system (see above).
For cars with K4M engine
Remove the intake silencer.
Remove the clamps and disconnect hoses 1, 2 and 4, Figures 13-14, from the thermostat housing (device for removing elastic clamps Mot. 1202 or Mot. 1448).
Figure 13-14 - Disconnecting the hoses from the thermostat housing of the K4M engine: 1 - engine cooling system radiator supply hose; 2 - expansion tank hose; 3 - hose holder; 4 - interior heater hose; 5 - coolant temperature sensor
Disconnect the wiring harness connector and remove the coolant temperature sensor (spanner 18).
Disconnect the hoses from the holder 3.
Unscrew nine bolts 1, Figure 13-15, fastenings and remove the thermostat housing 2 (8 mm socket, extension, ratchet wrench).
For cars with K7M engine
Remove the air filter air intake pipe.
Remove the clamps and disconnect hoses 1 and 2, Figure 13-16, from thermostat 3 (device for removing elastic clamps Mot. 1202 or Mot. 1448).
Figure 13-16 - Disconnecting the hoses from the K7M engine thermostat: 1 - expansion tank hose; 2 - engine cooling system radiator supply hose; 3 - thermostat
Loosen bolts 1, Figure 13-17, securing the thermostat housing (8 mm socket, extension, ratchet wrench).
Remove thermostat 2 with gasket.
The thermostat gasket needs to be replaced.
Figure 13-15 - Removing the thermostat housing of the K4M engine: 1 - mounting bolt; 2 - thermostat housing
Figure 13-17 - Removing the thermostat of the K7M engine: 1 - thermostat housing mounting bolt; 2 - thermostat
Installation
For vehicles with K4M engine Install a new thermostat housing gasket. Install the housing 2, Figure 13-15, of the thermostat.
Install and tighten the thermostat housing mounting bolts without tightening (replaceable head 8, extension, ratchet).
Tighten bolts 1...9 of the thermostat housing in the order shown in Figure 13-18 to the required torque in two stages (replaceable head 8, extension, torque wrench).
Figure 13-18 - Tightening order of the K4M engine thermostat housing mounting bolts: 1...9 - mounting bolts
Tightening torque of thermostat housing mounting bolts: Stage 1 - preliminary tightening 4 N·m (0.4 kgf·m);
Install the coolant temperature sensor and connect the wiring harness connector (spanner 18).
Install new clamps and connect hoses 1, 2 and 4, Figures 13-14, to the thermostat housing (device for removing elastic clamps Mot. 1202 or Mot. 1448).
Connect the hoses to the holder 3.
Install the intake noise muffler.
For cars with K7M engine
Install a new thermostat gasket.
Install thermostat 2.
Tightening torque of thermostat housing mounting bolts 1 Nm (0.1 kgf·m) (replaceable head 8, extension, torque wrench).
Install new hose clamps.
Connect hoses 1 and 2, Figure 13-16, to thermostat housing 3 (device for removing elastic clamps Mot. 1202 or Mot. 1448).
Install the air filter air intake pipe.
Operations for all vehicle configurations
Fill the engine cooling system (see above).
Install the engine crankcase guard.
Connect the ground wire terminal to the battery.
Bleed air from the engine cooling system (see above).