Don't overlook the water outlet covering the thermostat. Check for cracks, broken flanges, internal pitting and corrosion, and erosion at the hose neck (a common problem with most aluminum housings). The gasket surface must be flat and free from warping or deep scratches.
Scrape the mating surfaces on the thermostat housing and engine to remove all traces of old gasket material. Use care on aluminum because the soft metal can be easily scratched.
To keep debris out of the cooling system while the thermostat housing in removed, temporarily stuff a clean rag into the thermostat opening on the engine.
Install the new thermostat so the copper heat sensing element is toward the engine. If installed upside down, it won’t open.
Torque the thermostat housing bolts evenly and to the manufacturer's recommendations.
To insure air has been removed from the cooling system after replacing a thermostat, be sure to run the engine a few minutes, let it cool, and refill the antifreeze as needed.
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