Thermostat (1.8 l diesel) — removal and installation

Special tool

Coolant Hose Clamp Remover/Installer 303-397 (24-003)

Removal

1. Drain the coolant from the cooling system. For more information, refer to the Draining/Filling Coolant and Bleeding the Cooling System chapter in this section.

2. Remove the air deflector.



3. Disconnect the charge air cooler inlet pipe.



4. Disconnect the charge air cooler outlet pipe and disconnect the intake air temperature (IAT) sensor electrical connector.




5. Remove the charge air cooler outlet pipe.

• 1. Release the clamps.
• 2. Unscrew the nut.

6. Remove the charge air cooler.



7. Disconnect the coolant hose. Use a special tool.



8. Remove the thermostat cover.




9. Remove the thermostat.



10. Remove the thermostat O-ring and discard it as no longer needed.

Installation

CAUTION: Make sure that the inside of the ends of the charge air cooler inlet and outlet pipes are clean and free of oil, as this will reduce adhesion when installing the pipes to the charge air cooler. Failure to follow this instruction may result in engine damage.

1.

NOTE: Install a new thermostat O-ring.

Install the elements back in place in reverse order.