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Friday, 17 August 2012

DIY: Replace Engine Thermostat & Info

Thermostat plays an important role in maintaining the engine operating temperature as for engine, they need an ideal operating temperature in order for them working efficiently. How thermostats work for that? As the engine cold start, the thermostat valve will be closed, blocking the water flows to the radiator. Only after the engine warm and thermostat sensing the set point temperature, it will open the valve and allows the coolant to flows through the radiator for cooling up by the radiator fan or incoming air. The cooled coolant will be flow back to the engine block. Again, when the thermostat sensing cold coolant, it will close the valve and let the coolant circulate in the engine block until the temperature reached the set point before it open the valve for cooling.

What happen when the thermostat fails?
1.     Fail to open the valve - engine overheating if the thermostat fail to open the valve even though the coolant in the engine block boiling
2.     Fail to close the valve or without thermostat - Coolant will keep on flowing to the radiator and result to the engine fail to reach it ideal operating temperature that will result higher fuel consumption where Engine Control Unit (ECU) will send signal to rich up the fuel mix in order to get ideal temperature. For Vtec and MIVEC engine, low temperature mean that no Vtec/MIVEC. Vtec/MIVEC only function if engine in operating temperature. Beside that that, when cold start it will take time longer than before to warm up.
Alert with that, I decide to reinstall the thermostat with a new one. For five month, my perodua kancil cooling system work without thermostat after the mechanic removes it. He told me that this thing is "useless" after my car overheat because of failure thermostat. 

For this project, you will need
  • New thermostat
  • Thermostat housing gasket or gasket maker
  • scrapper
  • wrench no 12
  • New coolant
  • rack
I bought this thermostat with 82 degrees Celsius; RM45.00

Perodua Kancil Thermostat

First, drain the coolant. Draining point can be found below the radiator, refer picture below, with "mickey mouse ear" screw.

Draining screw in circle.

Draining  screw. Looks like "Mickey Mouse Ear"

Remove upper hose side at both sides; engine and radiator. For extra space, you can also remove distributor cover. 

Remove hose clamp as pointed in red arrow. You can also remove the distributor cover 

Using wrench no 12, remove two bolt of the thermostat housing. Clean it up with water.

Left: Thermostat housing, Right: Thermostat


Thermostat hole at the engine block

I forgot to buy the thermostat housing gasket, but luckily I have this; Gasket Maker


Black in color Gasket Maker
Install the thermostat like this.

Place the gasket maker around the surface that will be linked to engine block.

I have to wait for 10 minutes before the thermostat can be assembled, as per directions given by the Gasket Maker manufacturer. If you using paper gasket, you can assemble it instantly. Tighten the bolt and reattach the radiator hose and distributor cover. Refill the radiator with coolant start engine and checks for any leaking. Add some more coolant in the radiator until it full. Done!

Click HERE on how to check the thermostat

38 comments:

  1. SY PAKAI KERETA KANCIL ENGINE 660 STANDARD PERODUA, SY P KEDAI SPAREPART UTK BELI THERMOSTAT KANCIL 660 SY, TAUKE KEDAI BG THERMOSTAT SAMA SEPERTI GAMBAR DI ATAS....KEPALA THERMOSTAT TU NGAN HOUSING NGAM TP THERMOSTAT TU TERLEBIH PANJANG SEBAB ADA VALVE GETAH KAT BELAKANG DIA....THERMOSTAT STANDARD KANCIL X PANJANG MCM TU.....SY P KE KEDAI SPAREPART TU BALIK AND TAUKE TU KATA NIE THERMOSTAT KANCIL LA...L2 BOLEH MASUK, KANCIL PUN BOLEH MASUK...???SY P TANYA FOREMAN LAIN, DIA KATA MEMANG THERMOSTAT YG SY BELI TU LEBIH PANJANG DRPD YG STANDARD DISEBABKAN ADA VALVE EXTRA...HOUSING thermostat MIRA L2 DGN KANCIL 660 ADA BEZA KE? KOMEN SKT BRO?

    ReplyDelete
    Replies
    1. Tak pernah pula dengar isu pasal thermostat kancil panjang/pendek bro, apatah lagi mau bezakan housing thermostat Mira L2 & Kancil. Tapi bro, kalau dh pomen pn cakap yg u punya thermostat panjang dari standard, mmg x boleh pakai la tu. Cuba u cek kotak thermostat tu, ada tak tulisan "for Perodua Kancil" kt situ. Kalau cuma ada tulisan Mira L2 saja ada kemungkinan L2 dgn Kancil berbeza. Sebab tak semua barang L2 boleh masuk kt Kancil. Bagus u return balik part yg u beli tu, and pegi kedai sparepart lain pula, lagi bagus kalau u masih simpan thermostat kancil yg lama tu untuk buat perbandingan semasa beli nnti..

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  2. Bro nak tanye kalau suhu naik bila mula mula jalan kemudian turun bagi kancil 660, adakah disebabkan thermostat

    ReplyDelete
    Replies
    1. Bukan thermosat bro. cuba servis radiator dan periksa pusingan kipas laju atau perlahan. Enjin panas bila berhenti sebab radiator x dapat sejukkan air dengan sempurna. bila jalan, angin dari hadapan membantu menyejukkan radiator.

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  3. Boss sy ade masalah engine kancil 660sy terlalu mase berhenti..aircond pown mule rase kurang sejuk ,tp bile tngok tempreture kt dlm nmpak ok..bos rase ape maslah kerete sy

    ReplyDelete
    Replies
    1. cuba check kipas pusing kuat ke tidak.. kalau pusingan x kuat dri biasa, motor mau tukar.

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  4. boss,
    pagi pagi saya pi service radiator pasal ada leaking problem. Dah tukar top cover radiator lepas tu ok dah. takder problem leaking. Tapi temperature kereta drop masa bawah at highway....sebelum pi service temperature memang constant.......i balik semula ke kedai radiator dan explain kat dia tapi dia tak paham langsung....dia kata temperature turun bagus,,,mana bagus...sebelum dtg kereta you temperature always constant....i pun marah dgn dia dan pi kat perodua...tempat service kereta yang selalu saya service engine oil saya....dia kata radiator punya orang mungkin dah buang thermostat!!!....ok tak bawah kereta tanpa thermostat????

    ReplyDelete
    Replies
    1. Klau cuaca panas ok. Takda masalah.. tapi bila cuaca sejuk/hujan lebat temp akan jatuh lebih dr operating temp enjin. Bila ni berlaku, peeformance enjin kurang, fuel consumpatipn high..my suggestion, pakai balik thermostat. Lagi satu, klau xda thermostat, pagi start lambat enjin nk panas.

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    2. Bro nk tanya saya pakai kancil 850(A) baru buat top overhaul tapi bila tekan brake temperature naik..sebab ape tu bro..boleh bg penjelasan

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  5. yes boss, i nak pasang balik termostat...i perasan petrol cepat kurang baru baru ni....thanks bro

    ReplyDelete
  6. Boss saya ada masalah dengan timming kancil 660 manual, bila enjin dah panas timing turun lambat dari 2000rpm walaupun dah jalan jauh...bila berhenti matikan enjin biar dalam 15minit start balik timing okhay jd 1000rpm, bile bawak jauh sikit naik balik ke 2000rpm walaupun dah panas...apakah sebenarnya masalah kereta saya ini...timing naik dengan sendirinya walaupun enjin dah panas...

    ReplyDelete
    Replies
    1. Cuba check temperature bro..if temp enjin tinggi dr operating temp, rpm pn akan naik. Selain tu boleh cuba servis carburator..

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    2. Sometimes tolok jarum temp asal x bleh harap juga..enjin dh betul2 Panas baru naik jarum temp tu bro.. external water temp adalah yg terbaik utk monitor temp enjin

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  7. boss,produa kelisa 1.0 ada guna benda ini tak?

    ReplyDelete
  8. Salam bos,kancil sy time panas kena jolok pd bilah baru kipas pusing..kadang2 dia automatik pusing kalau panas..kalau nk baiki adakah kena tukar motor atau baiki connection atau tukar semua.tq bos

    ReplyDelete
  9. Salam boss kancil saya pakai enjin kelisa 1.0, sebelum servis radiator tempreture half je, tapi lepas servis time jalan tempreture turun suku tapi time berhenti tempreture half to ok x? Tapi rasa x de nmpak pun pasang thermostat pasang kat luar kan? Bukn dlm enjin , cuba explain

    ReplyDelete
    Replies
    1. temperature tu normal boss kalau separuh. bila behenti mmg temp naik sikit sbb xda angin tlg kipas sejukkan radiator. Thermostat kalau servis radiator mmg x nampak.. thermostat lekat kat enjin. luar enjin..

      Delete
  10. Salam, saya guna kancil 660 (m) masalah
    1. waktu pagi susah nak start.
    2. Bila saya buka lampu dpn dari terang jadi malap, radio akan jadi hidup mati hidup mati aircond akan jadi kurang sejuk.
    3. Bila saya matikan enjin kereta dan nak start balik batry jadi kosong. Macam batry kong. padahal batry da tukar baru. Adakah di sebabkan Thermostat boleh jadi masalah ni.

    ReplyDelete
    Replies
    1. Ni mcm masalah alternator. Tk bleh caj bateri. Try start n cabut terminal -ve bateri. Kalu enjin mati, alternator problem. Kalu tk, wiring problem.

      Delete
    2. Bukan thermostat.
      Boleh check alternator spt Saudara Meor ckp tu.. then, kalau alternator ok & bateri baru, saya sarankan untuk buat grounding wire yang baru.. Grounding wire (-ve) yang terlalu lama akan menyusutkan jumlah pengaliran cas elektrik ke badan kenderaan dan starter gagal dihidupkan.

      Delete
  11. Bos sy nk tnya sikit.. Meter temp kadang2 naik high lepas tu dlm 3 mnit turun normal balik. Adakah disebabkan thermostat??

    ReplyDelete
    Replies
    1. semasa idle atau bergerak?

      Rasanya bukan masalah thermostat. Ada kemungkinan sensor suhu perlu ditukar. Periksa kelajuan kipas radiator,

      Delete
  12. nk tnye skit bos..kereta kancil sy prob temp ..temp akn naik ble off aircond.tp ble on aircond temp pn trun blk..sbb thermostat ke msalah ni?

    ReplyDelete
  13. Kancil 660 sy bila cold start rpm sampai 4-5k. Dlm 5-8 min akan nornal. Ape masalahnya yer. Sy sudah adjust timing idle tp sama saja. Choke pon dah service xde beza. Kereta ni jd lepas hantar workshop tukar clutch. Hantar balik workshop tu kata lama2 oklah. Skrg dah dkt 6 bulan pon sama. Decided xnak htr lg workshop tu sbb selepas second htr radiator fan connector tak pasang bini bwk bau hangit mujur tak overheat jer.pastu perasan ada leaking dr gearbox rupanya dia tak ketatkan screw oild drain gearbox. Speedometer xjalan hon tak bunyi..nasib tak baik htr workshop mcm tu. Nak buat sendiri xde masa.

    ReplyDelete
  14. Salam sejahtera..mnta nasihat dri otai2..sy pkai enjin L2s gbox auto..masalah sy:
    1.masa driving n brake kreta nak brenti contohnya kat trafik light..enjin bgegar mcm nak mati..gbox mounting n enjin mounting da tukar..tpi msi lgi dlm keadaan yg sma.
    2.Msa driving...on aircond n bila nak brake nak brenti contohnya kat trfik light..rpm turun naik x steady...tpi klu aircond off xda pla kejadian mcm ni berlaku..
    Tolong2 dlu urg susa..Peace

    ReplyDelete
    Replies
    1. Throttle body kene check tu

      Delete
  15. salam sejahtera.


    saya guna kancil auto.

    start2 RPM dah memang tinggi dalam 2000 rpm.

    bila on aircond,kalau jam, temperature naik.
    sama jugak kalau kereta tengah tak bergerak ( parking kejap untuk pergi kedai dll) temperature pun naik.

    baru je servis radiator apa semua, still sama masalah.
    macam mana ye ? tq bro.

    ReplyDelete
    Replies
    1. Mungin kipas radiator berputar dengan perlahan. Solution tukar motor kipas radiator.

      Delete
  16. Salam sejahtera..setiap hari kereta kancil sy akan bergerak 40-50km ulang alik kerja..sampai rumah,biar kan enjin hidup (idle)..mati kan enjin,dengar bunyi air menggelegak dalam tangki air..bila tengok,air keluar dari tangki tu..tp sebelum ni,temp ok..thermostat problem ke?

    ReplyDelete
  17. Salam bos..sy pengguna l2s turbo..nk tnye skit psal temp bla jln.bla tekan myk temp trus naek.bla xtkan myk,temp trun blik.ape mslh tu?

    ReplyDelete
  18. Salam bos..sy pengguna l2s turbo..nk tnye skit psal temp bla jln.bla tekan myk temp trus naek.bla xtkan myk,temp trun blik.ape mslh tu?

    ReplyDelete
    Replies
    1. I pun ade masalah yg sama, bile bawa slow ok je xpi klu bw dlm 80 lebih temp naik. Klu bos dah settle problem tu blh share tak ape yg bos buat. I pun pkai l2s turbo

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    2. kebanyakan kancil turbo buang termostat, temp steady. alternatif untuk elak temp cepat naik.

      Delete
  19. I recently came across your blog and have been reading along. I thought I would leave my first comment. I don't know what to say except that I have enjoyed reading. Nice blog. I will keep visiting this blog very often. Best Programmable Thermostat

    ReplyDelete

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