Tools & supplies
- Metric socket set (8, 10, 12 mm typical), ratchet, extension
- Torque wrench (0–50 ft·lb, accurate in low range)
- Flat & Phillips screwdrivers
- Pliers (for hose clamps)
- Drain pan (coolant)
- Funnel
- Gasket scraper / razor blade / wire brush
- Shop rags and brake cleaner or degreaser
- New thermostat (correct temp rating for your vehicle — commonly 180°F/82°C for many 22R applications; verify part for your model)
- New thermostat gasket or O‑ring (OEM-style gasket recommended)
- New hose clamps (optional but recommended)
- New coolant or pre-mixed 50/50 antifreeze/water
- RTV gasket sealant (only if OEM calls for it; thin small bead)
- Gloves, eye protection
- Jack and jack stands (only if needed for access)

Safety precautions (read and follow)
- Work on a cold engine. Never open the cooling system cap or remove hoses while hot — pressurized scalding coolant is dangerous.
- Wear eye protection and gloves. Coolant is toxic — avoid skin contact and recycle properly.
- Support vehicle safely on jack stands if needed. Chock wheels.
- Disconnect negative battery only if you will be removing electrical components or the fan could contact you. If fan is mechanical, be aware it can move; do not crank engine with hands near fan.
- Have a drain pan and clean up spills immediately.

Step-by-step procedure
1) Preparation
- Park on level ground, engine cold. Engage parking brake.
- Remove air cleaner assembly and any intake ducting blocking access to thermostat housing.
- Place drain pan under radiator petcock or lower radiator hose.

2) Drain coolant low enough
- Open radiator drain petcock or loosen lower radiator hose briefly to drop coolant level below the thermostat housing level (you don’t need to completely drain the system, just below the housing). Collect coolant for reuse or disposal.

3) Access and remove upper radiator hose
- Loosen clamp(s) on upper radiator hose at the thermostat housing with pliers or screwdriver. Twist and pull the hose off the housing. If stuck, carefully cut the hose off or use a flat screwdriver to pry (take care not to damage housing).

4) Remove thermostat housing
- Locate the thermostat housing (front of head/intake — water outlet housing). Remove bolts holding housing (usually two). Use appropriate socket and extension.
- Support the housing as you remove the last bolt; it may come off with a little coolant spill.

5) Remove thermostat & gasket
- Note thermostat orientation: spring (small coil end) faces into engine block (toward cylinder head); the flange/valve side faces the housing/radiator. Remove the thermostat and old gasket.
- Inspect housing and mating surface on the head for corrosion or pitting.

6) Clean mating surfaces
- Scrape old gasket material carefully with a gasket scraper or razor. Clean both surfaces with a wire brush and brake cleaner. Remove all debris. Make sure mating surfaces are flat and clean.

7) Prepare new thermostat & gasket
- Verify thermostat orientation (spring toward engine). Install new gasket. If thermostat design uses an O‑ring, lightly coat O‑ring with coolant and seat it in groove. If OEM requires a small bit of RTV, apply a thin bead only where specified — do NOT block coolant passages or use excess.

8) Reinstall thermostat housing
- Position thermostat and gasket, seat housing onto head. Install bolts finger tight. Tighten evenly in a crisscross pattern. Torque to 8–12 ft·lb (11–16 N·m) — do not overtighten (risk stripping or cracking aluminum housing). If you have the exact Toyota spec for your year, use that.

9) Reattach hoses & clamps
- Reinstall upper radiator hose and new hose clamps if available. Ensure hose is fully seated and clamp is placed over the hose bead.

10) Refill coolant & bleed air
- Close drain petcock. Refill radiator with 50/50 coolant (or concentrate + distilled water per directions) using a funnel to reduce spills.
- Start engine with radiator cap off, heater set to hot and blower on medium. Let idle and warm up until thermostat opens (feel upper hose — it will suddenly get hot). Add coolant as air bleeds out to maintain level.
- Watch for leaks at housing and hose. When the engine reaches normal operating temperature and the coolant level stabilizes, install radiator cap.

11) Final checks
- With engine at operating temp, inspect for leaks, check heater operation, check gauge/temperature. Re-check coolant level after a short road test (air pockets settle) and top up if necessary.
- Dispose/rehab coolant properly.

How to use key tools
- Socket/ratchet: use correct size; use extension to reach bolts. Break bolts loose, then remove gently.
- Torque wrench: set to specified ft·lb, snug bolts in sequence, and apply slow, steady force until click/indication. This prevents cracking the housing.
- Gasket scraper/wire brush: remove old gasket without gouging metal. Hold scraper at a low angle and scrape gently.
- Pliers for clamps: compress spring clamps evenly and slide back; for worm-drive clamps use screwdriver.

Common pitfalls & how to avoid them
- Opening system while hot: risk of scalding. Always work cold.
- Incorrect thermostat orientation: spring must face engine/block. Wrong orientation prevents proper function.
- Reusing old gasket: leads to leaks. Always replace gasket/O‑ring.
- Overtightening housing bolts: aluminum housing can crack or threads strip. Use torque wrench and specs above.
- Not cleaning mating surfaces: old gasket remnants cause leaks and bad sealing. Clean thoroughly.
- Not burping air: air pockets cause overheating and poor heater operation. Run engine with cap off and heater on to purge air.
- Reusing old coolant without flushing if contaminated or old: coolant chemistry degrades; replace if uncertain.
- Damaging hoses removing them: use penetrating lubricant and careful twisting. Replace brittle hoses.
- Not checking surrounding components: corroded housing or stripped threads may require housing replacement; plan for this.

Replacement parts typically required
- Thermostat (correct temp rating for your engine/year)
- Thermostat gasket or O‑ring (use OEM style)
- Optional: thermostat housing (if cracked/corroded), upper radiator hose, new hose clamps, radiator cap if old, fresh coolant

End — follow disposal rules for old coolant; double‑check for leaks and re-torque bolts after initial heat cycles.
rteeqp73

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