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(/qs3/pubsys2/xml/en/manual/4021418/4021418-titlepage.html)

General Information
The thermostat controls the coolant temperature. When
the coolant temperature is below operating temperature,
coolant is bypassed to the inlet of the water pump. When
the coolant temperature reaches the operating range,
the thermostat opens, seals off the bypass, and forces
coolant to flow to the radiator or the keel cooler on QSL9
marine engines. The thermostat begins opening at 82°C
[180°F].

Note : Some applications use an original

equipment manufacturer (OEM) supplied remote
mounted thermostat. See equipment
manufacturer for location. See equipment
manufacturer service equipment for remote
mounted thermostat removal and installation
instructions.

 CAUTION 
Never operate the engine without a thermostat.
Without a thermostat, the path of least resistance
for the coolant is through the bypass to the pump
inlet. This will cause the engine to overheat.

An incorrect or malfunctioning thermostat can cause the

engine to run too hot or too cold.

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Leak Test
Note : The leak test portion of this procedure
does not apply to QSL9 keel cooled marine
engines. To test QSL9 keel cooled engines. Refer
to Procedure 008-014 in Section 8.
(/qs3/pubsys2/xml/en/procedures/45/45-008-
014.html)
The engine thermostat and thermostat seal must
operate properly in order for the engine to operate in the
most efficient heat range. Overheating or overcooling
will shorten engine life.

 WARNING 
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

 WARNING 
Coolant is toxic. Keep away from children and pets.
If not reused, dispose of in accordance with local
environmental regulations.

 CAUTION 
On marine engines, use caution when draining
coolant that coolant is not spilled or drained into
the bilge area. Do not pump the coolant overboard.
If the coolant is not reused, it must be discarded in
accordance with local environmental regulations.

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Drain the coolant. Refer to Procedure 008-018 in

Section 8. (/qs3/pubsys2/xml/en/procedures/45/45-008-
018-tr.html)

Remove the radiator hose from the water outlet

connection.

Use an electronic service tool to monitor the coolant

temperature, or install a thermocouple or temperature
gauge, which is known to be accurate, in the cylinder
block on the engine side of the thermostat.

Install a hose of the same size on the water outlet

connection. It must be long enough to reach a remote,
dry container used to collect coolant.

Install and tighten a hose clamp on the housing outlet.

Place the other end of the hose in a dry container.

 CAUTION 
Always vent the engine and aftercooler during
filling to remove air from the coolant system, or
overheating will result.

Fill the cooling system. Refer to Procedure 008-018 in

Section 8. (/qs3/pubsys2/xml/en/procedures/45/45-008-
018-tr.html)

Note : The engine coolant temperature must be

below the thermostat opening temperature to
perform this test.
Operate the engine at rated speed for 1 minute.

Shut the engine OFF and measure the amount of

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coolant collected in the container.

The amount of coolant collected must not be more than

100 cc [3.3 fl oz].

If more than 100 cc [3.3 fl oz] of coolant is collected, the

thermostat is leaking and must be replaced.

Complete the following test in-chassis to determine the

thermostat opening temperature.

Start the engine and monitor the coolant temperature

with INSITE™ electronic service tool or a gauge. Keep
the engine speed below 1500 rpm during the test.

Thermostat Initial Opening Temperature

celsius fahrenheit
81 MIN 178
83 MAX 182

Shut the engine OFF when the coolant starts to flow.

If coolant does not start flowing into the container during

the initial opening temperature range, the thermostat
must be replaced.

Preparatory Steps
All Applications Except Marine

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 WARNING 
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the
negative (-) battery cable last.

 WARNING 
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

 WARNING 
Coolant is toxic. Keep away from children and pets.
If not reused, dispose of in accordance with local
environmental regulations.

• Disconnect the batteries. See equipment

manufacturer service information.
• Drain the coolant. Refer to Procedure 008-018 in
Section 8.
(/qs3/pubsys2/xml/en/procedures/100/100-008-018-
tr.html)
• Remove the radiator hose from the water outlet
connection.

Marine Applications
 WARNING 
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

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 WARNING 
Coolant is toxic. Keep away from children and pets.
If not reused, dispose of in accordance with local
environmental regulations.

 CAUTION 
Use caution when draining coolant that coolant is
not spilled or drained into the bilge area. Do not
pump the coolant overboard. If the coolant is not
reused, it must be discarded in accordance with
local environmental regulations.

• Drain the engine coolant. Refer to Procedure 008-

018 in Section 8.
(/qs3/pubsys2/xml/en/procedures/100/100-008-018-
tr.html)
• On QSC8.3 and QSL9 engines with heat
exchangers, remove the coolant hose from the
water outlet connection.

• On QSL9 engines with keel cooling, remove the

coolant hose from the inlet side of the keel cooler
thermostat housing.

Remove
All Applications Except Marine
Remove the water outlet connection capscrews and
water outlet connection.

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Remove the thermostat.

Marine Applications
On marine engines with heat exchangers, remove the
water outlet connection capscrews and the water outlet
connection from the top of the cylinder head.

On QSL9 engines with keel cooling, remove the water

inlet connection capscrews and the water inlet
connection from the keel cooled thermostat housing.

Clean and Inspect for Reuse

Clean all of the mating surfaces.

Note : Do not let any debris fall into the

thermostat cavity when cleaning the surfaces.

Inspect the thermostat for damage.

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Inspect the thermostat gasket for damage. If the gasket

is damaged, it must be replaced.

The nominal operating temperature is stamped on the

thermostat. The thermostat must meet the following
criteria:

• The thermostat must begin to open within 1°C or 2°

F of this nominal temperature.
• The thermostat must be fully open within 12°C or
22°F of this nominal temperature.

The fully open distance between the thermostat flange

and housing is 9.4 mm [0.370 in].

Heat the water and check the thermostat as follows:

• Suspend the thermostat and a 100°C [212°F]

thermometer in a container of water.
• Do not allow the thermostat or the thermometer to
touch the sides of the container.

Clean and Inspect for Reuse

Clean all of the mating surfaces.

Note : Do not let any debris fall into the

thermostat cavity when cleaning the surfaces.

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Inspect the thermostat for damage.

Inspect the thermostat gasket for damage. If the gasket

is damaged, it must be replaced.

Suspend the thermostats and a 100°C [212°F]

thermometer in a container of water.

Note : Do not allow the thermostats or

thermometer to touch the container.
Heat the water slowly so the wax element in the
thermostats has sufficient time to react to the rising
water temperature.

Note : The normal operating temperature is

stamped on the thermostat.

Inspect the thermostats as follows:

• Thermostat must begin to open within 1°C [2°F] of

82°C [180°F].
• Thermostat must be fully open within 1°C [2°F] of
95°C [203°F].

Note : The fully open clearance between the

thermostat flow valve and flange must be 11.7
mm [0.46 in] minimum.

Install
All Applications Except Marine
Install the new thermostat into the water outlet
connection. Make sure the top and bottom o-rings are in
place. If the o-rings are damaged, replace with new
o-rings.

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Install the water outlet connection and mounting

capscrews.

Torque Value: 24 n•m [ 212 in-lb ]

Marine Applications
On QSC8.3 and QSL9 engines with heat exchangers,
install the thermostat into the water outlet connection.
Make sure that the top and bottom o-rings are in place.

Install the water outlet connection and mounting

capscrews.

Torque Value: 24 n•m [ 212 in-lb ]

On QSL9 engines with keel cooling, install the

thermostat into the water inlet connection of the keel
cooled thermostat housing.

Install the water outlet connection.

Torque Value: 24 n•m [ 212 in-lb ]

Finishing Steps
 WARNING 
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the
negative (-) battery cable last.

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 CAUTION 
Always vent the engine and aftercooler during
filling to remove air from the coolant system, or
overheating will result.

• Fill the cooling system. Refer to Procedure 008-018

in Section 8.
(/qs3/pubsys2/xml/en/procedures/100/100-008-018-
tr.html)
• Connect the batteries. Reference the equipment
manufacturer service information.
• Operate the engine and check for leaks.

Last Modified: 17-Mar-2017

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