How to replace the Thermostat of a Pajero/Montero diesel (3.2 DiD)

The thermostat has a major rule in keeping your engine working for a long happy life.

In the shorter term, it verifies that your engine will work in the right temperature and saves fuel.

The Diesel thermostat from 2001 to 2008 should be a 76.5C one. from 2009 and up, it should be 82C.

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Required tools:

10,12mm sockets

Wrench

High Quality RTV

That work should be done when the engine is COLD!

Here is the old thermostat:

1. Remove the air inlet by unscrewing the 2X 10mm bolts. You may remove the black plastic cover, but it is not a “must”.

2. Now you can see the lower radiator hose, one end of it connected to the radiator, the other (the higher one) to the thermostat housing.

Open the 2X 12mm bolts and pull the housing towards you. Be careful, some coolant will be spilled, remember to wash it. It is toxic and may kill animals that will  try to lick it.

3. Install the new thermostat: apply a thin layer of RTV on the rubber gasket, put it in place – the hole should point up! and close the housing with the bolts.

4. Let is dry for a while (20-30 minutes) and then start the engine while the radiator cup is open – we should let the air go out of the system and add coolant as needed.

Let the engine work for ~20 minutes, see that it reaches the working temp and not being overheated.

Carefully, close the radiator cup and only then turn the engine off.