Fel-Pro 35921 Thermostat Gasket Instruction Manual

1. Product Overview

The Fel-Pro 35921 Thermostat Gasket is an essential component designed to provide a reliable seal for your vehicle's thermostat housing. This gasket ensures proper sealing, preventing coolant leaks and maintaining the efficiency of the engine's cooling system. Fel-Pro gaskets are engineered with application-specific materials to meet or exceed original equipment specifications, offering dependable performance and durability.

Figure 1: Fel-Pro 35921 Thermostat Gasket. This image displays the Fel-Pro 35921 Thermostat Gasket. It is a black, circular sealing component designed for automotive thermostat housings. The gasket features a smooth, continuous ring with a small, molded tab or locator on its outer edge, indicating its specific design for proper fitment.

2. Safety Information

Always prioritize safety when working on automotive systems. Failure to follow proper safety procedures can result in injury or damage to the vehicle.

• Ensure the engine is cool before beginning any work on the cooling system to prevent burns from hot coolant or engine components.
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Disconnect the vehicle's battery before performing any electrical work or if there is a risk of accidental engine start.
• Dispose of old coolant responsibly according to local regulations.
• Refer to your vehicle's specific service manual for detailed instructions and torque specifications.

3. Package Contents

The package for the Fel-Pro 35921 Thermostat Gasket typically contains:

• One (1) Fel-Pro 35921 Thermostat Gasket

Inspect the package upon receipt to ensure all components are present and undamaged.

4. Vehicle Compatibility

The Fel-Pro 35921 Thermostat Gasket is compatible with various vehicle models. Always verify fitment for your specific vehicle before installation. This gasket is known to fit:

• 2009-2020 Kia Optima
• 2011-2020 Kia Sorento
• 2016-2018 Kia Sorento
• 2011-2021 Kia Sportage
• 2012-2013 Kia Forte5
• 2010-2013 Kia Forte Koup
• 2009-2010 Kia Magentis
• 2018-2021 Kia Stinger
• 2009-2012 Kia Rondo
• 2009-2021 Hyundai Sonata (and other Hyundai models as applicable)

It is crucial to confirm compatibility by entering your vehicle's year, make, model, engine, and trim information to ensure correct fitment.

5. Installation Instructions

Replacing a thermostat gasket requires mechanical aptitude. If you are unsure about any step, it is recommended to consult a qualified mechanic or refer to your vehicle's specific service manual for detailed procedures.

5.1. Tools and Materials Required

• Socket wrench set
• Pliers
• Drain pan
• New engine coolant (compatible with your vehicle)
• Scraper or gasket removal tool
• Clean rags
• Safety glasses and gloves

5.2. Installation Steps

1. Prepare the Vehicle: Ensure the engine is completely cool. Park the vehicle on a level surface and engage the parking brake.
2. Drain Coolant: Place a drain pan under the radiator and open the drain cock to drain the engine coolant. Some coolant may also drain when the thermostat housing is removed.
3. Locate Thermostat Housing: Identify the thermostat housing, typically located where the upper radiator hose connects to the engine.
4. Remove Hoses and Wiring: Disconnect any hoses (e.g., upper radiator hose) and electrical connectors attached to the thermostat housing. Use pliers for hose clamps.
5. Remove Thermostat Housing: Loosen and remove the bolts securing the thermostat housing. Carefully remove the housing. Be prepared for additional coolant to spill.
6. Remove Old Gasket and Thermostat: Remove the old thermostat and the old gasket. Inspect the thermostat for proper operation if it is also being replaced.
7. Clean Sealing Surfaces: Thoroughly clean both mating surfaces (on the engine block/intake manifold and the thermostat housing) to remove all traces of the old gasket material, corrosion, and debris. A gasket scraper can be used carefully to avoid damaging the surfaces.
8. Install New Gasket: Place the new Fel-Pro 35921 Thermostat Gasket onto the thermostat or into the housing, ensuring it is correctly seated. The gasket's design often includes a tab for proper orientation.
9. Reinstall Thermostat Housing: Position the thermostat (if removed) and then carefully place the housing back onto the engine, aligning it with the bolt holes.
10. Tighten Bolts: Insert the housing bolts and hand-tighten them. Then, using a torque wrench, tighten the bolts to the manufacturer's specified torque settings. Tighten in a crisscross pattern if there are multiple bolts to ensure even pressure.
11. Reconnect Hoses and Wiring: Reattach all hoses and electrical connectors securely.
12. Refill Coolant: Refill the cooling system with the appropriate type and amount of new engine coolant.
13. Bleed Air: Start the engine and allow it to reach operating temperature. Monitor the coolant level and add more as needed. Bleed any air from the cooling system according to your vehicle's service manual. Check for leaks.

6. Maintenance

Regular inspection of your vehicle's cooling system components, including gaskets, can help prevent issues.

6.1. Inspection

• Periodically check around the thermostat housing for any signs of coolant leaks, such as drips, stains, or residue.
• Inspect the condition of the hoses connected to the thermostat housing for cracks, swelling, or softness.

6.2. Replacement Intervals

Thermostat gaskets are typically replaced whenever the thermostat or thermostat housing is removed for service. While there isn't a fixed replacement interval for the gasket itself, it is considered a single-use item and should always be replaced with a new one during any cooling system repair involving the thermostat housing to ensure a proper seal.

7. Troubleshooting

If you encounter issues after installing the thermostat gasket, consider the following common problems and solutions:

• Coolant Leak from Thermostat Housing:
  • Cause: Improperly cleaned sealing surfaces, incorrect gasket installation, overtightened/undertightened bolts, or a damaged gasket.
  • Solution: Re-check bolt torque. If the leak persists, drain coolant, remove housing, inspect gasket for damage, ensure sealing surfaces are perfectly clean and flat, and reinstall with a new gasket if necessary.
• Engine Overheating/Underheating:
  • Cause: While not directly caused by the gasket, an improperly installed thermostat (if replaced) or air trapped in the cooling system can lead to temperature issues.
  • Solution: Ensure the cooling system is properly bled of air. Verify the thermostat is installed correctly and functioning.

If troubleshooting steps do not resolve the issue, seek assistance from a certified automotive technician.

8. Specifications

9. Warranty and Support

Fel-Pro products are manufactured to high standards. For specific warranty information or technical support regarding the Fel-Pro 35921 Thermostat Gasket, please refer to the official Fel-Pro website or contact their customer service directly. Keep your purchase receipt as proof of purchase.

Manufacturer: Fel-Pro

Website: www.felpro.com