Hey guys,

Recently my thermostat jammed up (closed) and my engine overheated, Ego came to the rescue and told me exactly what it was - Called the NRMA and they came to pull it out (Jason was willing to, but had prior engagements).

So, running a while without a thermostat, the time came to replace it. Instead of spending a rediculous amount paying somebody to fix it I decided it would be an easy fix and employed a friend to help out.

So - here he is, Peter_Pan or Pete.
http://img179.imageshack.us/img179/7097/21122008021xp8.jpg

Requirements -
- A socket wrench set
- A phillips head screwdriver
- A thermostat suited to a TE-TW
- A thermostat gasket suited to a TE-TW

----

So, the first step in replacing the thermostat was to remove the entire air intake system (MAF, intake pipes, snorkel, air box, and air filter) - This allows for easy access to the piping containing the thermostat.
http://img247.imageshack.us/img247/9148/21122008029xr1.jpg
Now, release all coolant from the system to when you open your thermo housing you don't flush it that way! Bottom of the radiator, drivers side.

Once you have the air intake off, you must then remove the bolt holing some wires to the water intake (the water intake is the lower radiator pipe running to the engine, this is where the thermostat is located, once you have this off you will be able to undo the bolts to the thermostat housing. Find this where the hands are in the above picture.

Now everything is clear and you are ready to remove your existing thermostat, on thermostat housing, there are 3 bolts, undo these bolts and you will be able to pull it right out. Undo these 3 bolts, and slide out your existing thermostat.

http://img380.imageshack.us/img380/6581/21122008032bp9.jpg

Now you have your existing thermostat out, you may prepare the new one. This new one needs the gasket placed around the ring of the thermostat, and then insert in to the housing with the longer end going towards the engine, and the shorter end going to the radiator piping.

http://img187.imageshack.us/img187/477/21122008027bz4.jpg
http://img168.imageshack.us/img168/5957/21122008030ih7.jpg


Once you have done this, bolt the housing back together and ensure it is just as tight as it previously was, you may now bolt the wires back to the housing, and reassemble the air intake system, and you are all done, the new thermostat has been installed!


DISCLAIMER: I TAKE NO RESPONSIBILITY FOR ANY DAMAGE CAUSED ATTEMPTING THIS REPAIR, IF YOU ARE NOT CONFIDENT DOING THIS HIRE A QUALIFIED MECHANIC!

Heh - I had to pay for a thermostat install a few weeks ago in Kalgoorlie when ours stuffed itself near Caiguna Roadhouse (370 km east of Norseman). We waited there (4 hours) for a (4 hour) tow to Norseman where the mechanics agreed it was a stuffed thermostat and they cut the valve out of mine and sent us 200 km on our way to Mitsubishi in Kal.

It cost lots of dollars to have them do it for me, but with most of my tools back in Canberra... I got some newly leaking spark plug oil seals replaced at the same time, too.

Not nice to see the temp gauge go up fast in the middle of nowhere.

We're 7 weeks into a 26 week trip around Australia... no winter for us this year!

Just wanted to say thanks for the pictorial its helped alot. Just done mine as the large thermo was staying on. I was quoted a price of $275 to have it changed by my mechanic WHEN I picked my self off the floor I went straight to the club site after a bit of searching found your post.
I got a genuine thermostat for $39.05 and coolent $21.00 it took me about an hour problym solved. So once again thanks for the help.

(1) You forgot to mention that the 'jiggle' valve must be at the top.

(2) I just replaced the thermostat in my car. I called Repco & Auto-one; looked at ebay and googled thermostat prices. They ranged from $48 to $80 plus on top of that you need the rubber ring gasket for an extra $7 to $9. I thought all that was quite expensive so I decided to call my local Mitsubishi dealer and the genuine product was only $32. In addition, it is much better built than the aftermarket units; made from stainless steel, and; has a rubber seal on the fluid valve which the aftermarket units do not. The $32 also included the rubber ring gasket which was fitted to the thermostat.