User Manual

200 ENGINE ASSEMBLY
Page 6-73
[215 NU, NG & LD]
THERMOSTAT, THERMOSTAT
HOUSING, THERMOSTAT
SEAL AND COOLANT
CONDITIONER
Refer to Figure 6-90.
1. When replacing a seal for any reason,
examine the surface of the thermostat
sleeve, the bore area and the seal to prevent
premature failure of the new seal. A sealing
lip that has been turned back, cut or
otherwise damaged will leak and must be
replaced. The lip faces the front of the
engine.
2. Remove any surface nicks, burrs, sharp
edges and tool marks from the thermostat
sleeve and housing bore area using crocus
cloth.
3. Check to see that replacement seals are
free from any contaminants such as chips,
grit, dust, or any other debris that would
prevent the seal from properly seating in the
thermostat housing.
4. Press the seal into the housing bore with
smooth, uniform pressure using seal
installation tool J 26637-A and driver handle
J 8092.
Tool J 26637-A is designed to regulate
thermostat seal installation depth. The shoulder
on the tool bottoms on the thermostat bore of the
housing to prevent the seal from being installed
too far.
Wherever possible, an arbor press should be
used to apply assembly pressure. Do not apply
hammer blows or uneven pressure directly to
seal surfaces. Precautions should be taken
against cocking of seal throughout the installation
operation. Make sure the seal is not cocked when
installed.
5. Position thermostat (7) in the housing (5)
with jiggle pin or caged ball up.
6. Install a gasket (8) on the housing mounting
surface.
7. Position housing assembly on the coolant
manifold (9) mounting surface.
8. Secure in position with two lower mounting
capscrews (13).
9. Position a check valve assembly (3) in the
coolant conditioner head assembly (2). The
ball end of the check valve must be inserted
first.
10. Position an O-ring (4) in the O-ring recess of
the head assembly.
11. Install head assembly (2) on the thermostat
housing (5) and secure with capscrews (1).
12. Torque capscrews to 25 lb-ft (34 N폷m) using
torque wrench J 24406 or equivalent.
13. Apply a light film of oil on the face of the
coolant conditioner filter gasket seal.
14. Install the coolant conditioner filter element
(14). Turn the coolant conditioner filter one
full turn after gasket contacts base. Use tool
J 24783 to tighten.
5-101.bk Page 73 Friday, March 17, 2006 11:05 AM