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Thermostat replacement in Jimny VVT (DOHC) - pain in the A$$

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25 Apr 2017 07:02 - 25 Apr 2017 07:09 #180541 by asypeer
Hi,
I heard that access to the thermostat in the DOHC is bad - till yesterday - I now know its very bad :)
I bought an original Suzuki thermostat a few months ago and now its time to install it. yesterday I began to do it (not finished yest, luckily the Jimny is not my DD)

steps:
1. cold engine - as the coolant might be hot and other pipes can cause burns.
2. Drain coolant from the radiator - open the plastic tap in the radiator and let the coolant drip to a container (its not something your dog / cat should leak as its toxic)
3. remove air filter (4 latches of the air box)
4. remove air box and hose from intake manifold (2 stainless bands that can be loosen with 10 mm wrench in both ends, disconnect MAF sensor, 1 10mm bolt holds the air hose to the engine chassis)
5. remove all sensors from throlttle (3 sensors), remove 2 coolant hoses going connected to the intake manifold
6. remove throttle cable from throttle body
7. release 4 10mm bolts of the throttle body
8. lift throttle body and remove it (note the gasket will probably will need replacement, in my case it was torn to pieces...
I will clean the throttle body with some carburetor cleaner as its full of soot deposits, also the inlet manifold could use some cleaning
its important to cover the inlet manifold with some plastic bag or cloth. you DO NOT want any bits / Bolts / dirt going into there.
9. in order to have better access to the thermostat housing with a wrench (3 10mm bolts, we'll get to that..) I also removed the hose from the PCV valve.
10. unbolt the 2 visible bolts from the thermostat housing (10mm)

Now to the issue that causes me a major delay - the 3rd housing bolt of the thermostat housing, the lower one which can't be seen from the engine front. - I was not able to access it with a 3/8 or 1/4 wrench. with extenders or without. the access is so bad that it too me 2 hours to release the bugger. I still do not know how I'm going to get back it back to its place.. maybe a flexible extension. royal pain!

anyways, I will keep updating this thread with pictures and other thoughts - I'll get back to that this evening.
any tips ?? how do I remove the old thermostat from its housing ? flat screwdriver?

thanks!!
Assaf
Last edit: 25 Apr 2017 07:09 by asypeer.

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25 Apr 2017 09:20 #180547 by Keithy
Sounds like you're enjoying yourself!

Is the stat faulty?

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25 Apr 2017 12:12 #180549 by asypeer
I'm not sure it's faulty, summer is coming and last summer my jimny almost overheated. I have a feeling the thermostat might be faulty. Its also a good opportunity to give the cooling system a proper wash..

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25 Apr 2017 18:59 #180577 by helijohn

asypeer wrote: Now to the issue that causes me a major delay - the 3rd housing bolt of the thermostat housing, the lower one which can't be seen from the engine front. - I was not able to access it with a 3/8 or 1/4 wrench. with extenders or without. the access is so bad that it too me 2 hours to release the bugger. I still do not know how I'm going to get back it back to its place.. maybe a flexible extension. royal pain!

anyways, I will keep updating this thread with pictures and other thoughts - I'll get back to that this evening.
any tips ?? how do I remove the old thermostat from its housing ? flat screwdriver?

thanks!!
Assaf


That sounds like a right game.

Do it right - use Hammerite
When the blue light is flashing I am kidding.

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26 Apr 2017 04:13 #180590 by asypeer

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26 Apr 2017 04:17 #180591 by asypeer

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26 Apr 2017 04:56 #180594 by helijohn

asypeer wrote: how do I remove the old thermostat from its housing ? flat screwdriver?

thanks!!
Assaf


I do, If it is stuck in the housing I get a lever, not necessarily a screwdriver, under the bell shaped top and pop the stat out from there. I just did that a few months ago on my Junior as it happens.

Do it right - use Hammerite
When the blue light is flashing I am kidding.

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26 Apr 2017 06:16 - 26 Apr 2017 06:20 #180599 by asypeer
Eventually I was able to remove it pretty easily using pliers. Was not glued as I thought..
Any thoughts about cleaning the intake manifold while I have good access? Already cleaner the throttle body with carb cleaner..
What about ruining the engine without a thermostat and some laundry powder to give it a proper clean?
Last edit: 26 Apr 2017 06:20 by asypeer.

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26 Apr 2017 06:19 #180601 by helijohn

asypeer wrote: Eventually I was able to remove it pretty easily using pliers. Was not glued as I thought..


Yeah, they often get sort of corroded in place a little but usually come out without too much fuss.

Do it right - use Hammerite
When the blue light is flashing I am kidding.

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26 Apr 2017 09:54 - 26 Apr 2017 09:56 #180602 by yakuza
I just had this out last week while doing my engine swap.
I think i would remove or loosen the complete intake manifold instead of just the throttle body. Again. But now i know how to and where it all hooks up.

Could maybe access the thermostat from above if you loosen the intake manifold from the engine, and press it against the wing/battery.

The same goes if i should change the starter motor.
will be very difficult to change that one as well without removing the intake manifold.
Maybe easier if you got a lift for the car and can access starter from underneath.

Actually had to remove my manifold twice because i thought i could get the engine and starter and gearbox to meet up and become friends with the intake manifold still on the engine. But i was wrong.. It was easier to remove the complete intake manifold again to make sure everything was in place underneath..

Norway 2005 Jimny M16A VVT, 235 BFG MT, 2" Trailmaster, ARB rear lck, 17%/87% high/low gears.
Last edit: 26 Apr 2017 09:56 by yakuza.

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26 Apr 2017 11:56 #180605 by asypeer
Hi, I was able to remove the thermostat. I guess it would be OK to get it back.
I was thinking maybe it's good opportunity to give the cooling system a proper wash (half a glass of laundry powder into the radiator without a thermostat and then wash it with clean water for several cycles till it's clean.
As for the intake manifold, I'm not planning to remove it so i guess cleaning it is not a good idea as all the crap would go straight into the engine..

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30 Apr 2017 11:18 #180731 by asypeer
Was able to replace the thermo, the old one seems to be OK. Cleaned it from some light rust and it looks as new. Open in boiled water.
I also cleaned the throttle body, replaced the gasket and gave a minor clean to the intake manifold.
After everything was re-assembled - I flushed the cooling system with some distilled water and then fresh 50% 50% coolant (peak).
No leaks so far ;)

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