Thermostat unit - r+r

Operation 1088C30 · WATER PUMP AND THERMOSTAT

Removing

Place the car on a ramp.

- 7055B54 under-engine guard - r r

- 5530B10 battery - r+r

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

Fit a suitable container for coolant recovery.

1. Remove retaining collar (1a) and disconnect coolant entry sleeve (1b) on the thermostat side.

2. Undo retaining screws (2a) and remove thermostat assembly (2b)

Removing

Place the car on the ramp.

Disconnect the battery negative terminal.

- 5530B10 battery - r+r

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

- 1048A32 sleeve from air cleaner to intake manifold - r + r

- 1048A10 air cleaner filtering element - replace

- 7055B54 under-engine guard - r r

1. Disconnect the electrical connection from the engine coolant temperature sensor.

2. Disconnect the coolant supply and return hoses to the radiator from the thermostat.

Recover the coolant which comes out in a suitable container.

3. Disconnect the coolant return pipe to the reservoir from the thermostat.

4. Disconnect the coolant supply pipe to the heater from the thermostat.

5. Disconnect the coolant supply hose to the water pump from the thermostat.

6. Undo the bolt (6a) and move the wiring mounting bracket (6b).

7. Undo the nuts (7a) and remove the thermostat (7b), complete with gasket.

Removing

Place the car on a ramp.

- 7055B54 under-engine guard - r r

- 5530B10 battery - r+r

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

Place a container under the vehicle to collect the engine coolant.

Drain the engine cooling system.

1. Disconnect the electrical connection from the engine temperature sensor.

2. Disconnect the coolant hoses from the thermostat.

3. Undo the bolts (3a) and remove the bracket (3c) joined to the rigid water pipe.

4. Unscrew the retaining bolts

5. Remove the thermostat from the cylinder head.

Removing

Position the vehicle on the ramp.

Proceed with the removal - 1044B10 fuel filter assembly - r + r or replace.

Proceed with the removal - 5530B10 battery - r+r.

Proceed with the removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R..

Proceed with the removal - 7055B54 under-engine guard - r r.

1. Disconnect the lower coolant inlet hose from the radiator, radiator side.

Manually press the springs and remove the rapid attachment.

Collect the coolant in a suitable container.

Refitting

Fit thermostat assembly into the housing on the cylinder head.

Tighten the bolts securing the thermostat assembly to torque.

Connect the coolant intake pipe and secure it with the appropriate retaining collar.

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

- 5530B10 battery - r+r

- 0010T21 coolant check density and top up if necessary

- 7055B54 under-engine guard - r r

Remove the vehicle from the ramp.

Refitting

Check the condition of the thermostat.

Thoroughly clean the thermostat and cylinder head mating surfaces.

Change the thermostat gasket.

Fit the thermostat, complete with gasket, and fix it tightening the nuts to the recommended torque.

Connect the coolant return hose to the water pump to the thermostat.

Connect the coolant supply pipe to the heater to the thermostat.

Connect the coolant return pipe to the tank to the thermostat.

Connect the coolant supply and return hoses to the radiator to the thermostat.

Connect the electrical connection to the engine coolant temperature sensor.

- 0010T20 coolant change

- 1048A10 air cleaner filtering element - replace

- 1048A32 sleeve from air cleaner to intake manifold - r + r

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

- 5530B10 battery - r+r

- 7055B54 under-engine guard - r r

Connect the battery negative terminal.

Remove the car from the ramps.

Refitting

Fit the thermostat in its seat on the cylinder head.

Tighten the fixing bolts to torque.

Tighten the bolts and the nut securing the bracket to the rigid coolant pipe.

Connect the coolant hoses to the thermostat.

Connect the electrical connection to the engine temperature sensor.

- 5530B52 Battery DRIP TRAY/SUPPORT - R.R.

- 5530B10 battery - r+r

- 0010T21 coolant check density and top up if necessary

- 7055B54 under-engine guard - r r

Remove the vehicle from the ramp.

1. Loosen the band (1a) and disconnect the T connector (1b) from the turbocharger air inlet hose.

1. Loosen the band (1a) and disconnect the turbocharger air inlet hose (1b), turbocharger side.

1. Disconnect the electrical connection from the air flow meter.

1. Loosen the band (1a) and remove the turbocharger air inlet hoses (1b) complete with air flow meter (1c).

1. Undo the bolts (1a) and (1b) and remove the rigid pipe from the E.G.R. solenoid valve to the throttle casing (1c).

2. Remove the gaskets.

1. Disconnect the electrical connection from the E.G.R. valve.

1. Undo the bolts (1a) and disconnect the water/exhaust gas heat exchanger for the E.G.R. system (1b) from the E.G.R. solenoid valve.

2. Undo the bolts (2a) and remove the E.G.R. system solenoid valve (2b).

3. Remove the bracket.

1. Release the vacuum pipe from the retaining band.

2. Disconnect the vacuum pipe from the pneumatic valve on the electro-pneumatically controlled throttle body.

3. Loosen the band and disconnect the oil vapour recovery pipe from the tappet cover.

4. Loosen the band fixing the air inlet hose to the electro-pneumatically controlled throttle body.

1. Undo bolts (1a) and remove the pneumatic throttle body (1b).

2. Remove the gasket.

1. Disconnect the electrical connection from the turbocharger vane actuator solenoid.

2. Release the turbocharger vane position actuator solenoid valve from the protection on the gearbox.

1. Undo the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

2. Loosen the band and disconnect the radiator upper coolant inlet hose from the thermostat.

3. Loosen the band and disconnect the outlet pipe from the climate control system heater (3a) from the thermostat T-connector and the delivery pipe to the rigid fluid intake pipe to the coolant pump (3b).

4. Loosen the band and disconnect the coolant supply pipe to the climate control system heater.

5. Loosen the band and disconnect the coolant return pipe to the coolant reservoir from the thermostat.

1. Loosen the bands and disconnect the coolant intake pipe (1a) and the coolant outlet pipe (1b) from the EGR exhaust gas heat exchanger.

1. Disconnect the electrical connections from the injectors and move the wiring aside.

1. Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.

1. Undo the nut fixing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.

2. Undo the pin (2a) and the bolt (2b) and remove the thermostat (2c) together with the water/exhaust gas heat exchanger for the E.G.R. system (2d).

3. Remove the thermostat seal.

Refitting

1. Place the water/exhaust gas heat exchanger for the E.G.R. system (1a) back in its housing together with the thermostat (1b) and the seal (1c).

2. Tighten the pin (2a) and the bolt (2b) fixing the thermostat to the recommended torque.

3. Tighten the nut securing the EGR water/exhaust gas heat exchanger to the cylinder head.

Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.

Place the electrical wiring back in its housing and connect the electrical connections to the injectors.

Connect the engine coolant inlet pipe and the engine coolant outlet pipe to the E.G.R. exhaust gas heat exchanger, then tighten the bands.

Connect the coolant return pipe to the coolant reservoir to the thermostat and tighten the band.

Connect the coolant supply pipe to the climate control system heater to the thermostat and tighten the band.

Connect the outlet pipe from the climate control system heater and the delivery pipe to the rigid inlet pipe to the coolant pump from the thermostat T-connector, then tighten the bands.

Connect the upper coolant inlet hose to the radiator to the thermostat and tighten the band.

Connect the electrical connection to the engine coolant temperature sensor.

Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

Fasten the turbocharger vane position actuator solenoid valve to the protection on the gearbox.

Connect the electrical connection to the turbocharger vane actuator solenoid.

1. Replace the pneumatically-controlled throttle casing (1a), complete with gasket (1b), back in its housing and fix it tightening the bolts to the recommended torque.

Tighten the band securing the air inlet hose to the electro-pneumatically controlled throttle body.

Connect the oil vapour recovery pipe to the tappet cover and secure with a band.

Connect the vacuum pipe to the pneumatic valve on the electro-pneumatically controlled throttle body.

Fix the vacuum pipe to the securing band.

Refit the E.G.R. system solenoid with bracket and tighten it using the bolts.

Connect the water/exhaust gas heat exchanger for the E.G.R. system to the E.G.R. solenoid valve and tighten the bolts.

Connect the electrical connection to the E.G.R. valve.

Refit the rigid pipe from EGR solenoid to throttle body in its housing complete with gasket and fix it with the bolts.

Place the turbocharger air inlet hoses back in their housings complete with air flow meter and tighten the band.

Connect the electrical connection to the air flow meter.

Connect the turbocharger air inlet hose, turbocharger side and tighten the band.

Connect the T connector to the turbocharger air inlet hose and tighten the band.

Connect the lower coolant outlet hose to the radiator.

Proceed with the refitting - 7055B54 under-engine guard - r r.

Proceed with the refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R..

Proceed with the refitting - 5530B10 battery - r+r.

Proceed with the refitting - 1044B10 fuel filter assembly - r + r or replace.

Refill the engine cooling system with coolant - 0010T20 coolant change.

Remove the car from the ramp.