🔧 Thermostat - Replacement

The thermostat on your Outback helps control engine temperature by regulating coolant flow. If it sticks open, the engine runs too cool; if it sticks closed, it can overheat quickly. This job involves draining some coolant, removing the thermostat housing, and installing a new thermostat with a fresh seal.

Difficulty Level: Intermediate | Estimated Time: 2-3 hours

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⚠️ Safety & Precautions

• Work only on a completely cold engine. Hot coolant can cause severe burns.
• Keep the radiator cap closed until the engine is cool.
• Use jack stands if you raise the front of the vehicle. Never rely on a jack alone.
• Dispose of used coolant properly. Keep it away from pets and children.
• No battery disconnect is required for this repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 12mm socket
• Ratchet
• Short extension
• Torque wrench
• Drain pan
• Flat-blade screwdriver
• Pliers
• Funnel
• Jack stands
• Floor jack (rated 3-ton minimum)
• Safety glasses
• Nitrile gloves
• Shop towels

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Thermostat - Qty: 1
• Thermostat gasket or seal - Qty: 1
• Engine coolant - Qty: 1 to 2 gallons
• Distilled water - Qty: 1 to 2 gallons

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📋 Before You Begin

• Park on level ground and let the engine cool completely.
• Set the parking brake and open the hood.
• If needed, raise the front end slightly for easier access to the lower radiator drain.
• Have a clean container ready to catch coolant.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Drain the coolant

• Place a drain pan under the radiator drain area.
• Use a flat-blade screwdriver or pliers to open the radiator drain cock.
• Drain enough coolant so the level drops below the thermostat housing.
• Close the drain cock when the flow slows to a drip.

Step 2: Remove intake ducting and access parts

• Use a 10mm socket and ratchet to remove any intake duct or air box fasteners blocking access.
• Move hoses or clips aside carefully so you can reach the thermostat housing.
• Take a photo before removing hoses.

Step 3: Remove the thermostat housing

• Use a 10mm socket and short extension to remove the thermostat housing bolts.
• Pull the housing straight off and catch any remaining coolant in the drain pan.
• Remove the old thermostat and gasket or seal.
• Clean the mating surfaces with a shop towel. Do not scratch the aluminum housing.

Step 4: Install the new thermostat

• Install the new thermostat in the same orientation as the old one.
• Install the new gasket or seal.
• Set the housing in place and start the bolts by hand.
• Use a torque wrench to tighten the housing bolts to 18 Nm (13 ft-lbs).

Step 5: Reinstall removed parts

• Reinstall any intake ducting, clips, or brackets removed earlier.
• Use a 10mm socket to snug fasteners securely.
• Reconnect any hoses or connectors moved out of the way.

Step 6: Refill and bleed the cooling system

• Mix coolant and distilled water if using concentrate.
• Use a funnel to refill the radiator and overflow tank.
• Start the engine with the heater set to hot and the fan on low.
• Let the engine idle until warm and watch for bubbles in the funnel.
• Add coolant as the level drops.
• When bubbles stop and heat comes from the vents, install the radiator cap.

Step 7: Check for leaks and verify operation

• Inspect the thermostat housing, drain cock, and hose connections for leaks.
• Let the engine reach full operating temperature.
• Confirm the temperature gauge stays steady and the heater blows hot air.

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✅ After Repair

• Recheck coolant level after the engine cools down fully.
• Top off the overflow tank if needed.
• Drive the vehicle and verify normal temperature operation.
• Check again the next day for any coolant seepage.

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💰 DIY vs Shop Cost

Shop Cost: $450-$800 CAD (parts + labor)

DIY Cost: $70-$180 CAD (parts only)

You Save: $300-$620 CAD by doing it yourself!

Shop labor rates vary but typically run $140-$220/hour. This repair takes a shop approximately 2-3 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.