| Removal and Installation Special Tool(s) | | Remover/Installer, Hose Clamp 303-397 (24-003) | Removal All vehicles | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
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Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
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Remove the air deflector. | | | -
NOTE:Make a note of the orientation of the retaining clamp. Disconnect the charge air cooler intake pipe. - Discard the retaining clamp.
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NOTE:Make a note of the orientation of the retaining clamp. Disconnect the charge air cooler outlet pipe and the intake air temperature (IAT) sensor electrical connector. - Discard the retaining clamp.
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Remove the charge air cooler. | | | -
Using the special tool disconnect the coolant hose. | Vehicles with 75 PS or 90 PS diesel engine | | -
Disconnect the glow plug wire electrical connector. | All vehicles | | -
Detach the oil level indicator and secure it to one side (vehicles with 75 PS or 90 PS diesel engine shown, vehicles with 115 PS diesel engine similar). | | | -
Disconnect the coolant hose (vehicles with 75 PS or 90 PS diesel engine shown, vehicles with 115 PS diesel engine similar). | Vehicles with 75 PS or 90 PS diesel engine | | -
Disconnect the coolant hose. | | | -
Remove the thermostat housing. | Vehicles with 115 PS diesel engine | | -
Disconnect the inlet metering valve electrical connector. | | | -
Detach the wiring harness from the thermostat housing and secure it to one side. | | | -
Remove the thermostat housing retaining bolts. | | | -
Disconnect the coolant hose and remove the thermostat housing. | Installation All vehicles NOTE:Make sure the insides of the charge air cooler outlet and intake pipes are clean and free from any oil residue as this will reduce the installation grip of the pipes to the charge air cooler. Failure to follow this instruction may result in damage to the engine. | | -
NOTE:Install a new thermostat housing gasket. To install, reverse the removal procedure. | Vehicles with 75 PS or 90 PS diesel engine Vehicles with 115 PS diesel engine All vehicles NOTE:Install a new retaining clamp. NOTE:Make sure the retaining clamp is installed in the same orientation as when removed. NOTE:Install a new retaining clamp. NOTE:Make sure the retaining clamp is installed in the same position as when removed. | | -
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
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