Thermostat (1.8 l diesel) — removal and installation

Special tool

Coolant hose clamp remover/installer 303-397 (24-003)

Withdrawal

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

2. Remove the air baffle.



3. Disconnect the charge air cooler inlet pipe.



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




5. Remove the charge air cooler outlet pipe.

• 1.Release the clips.
• 2. Loosen 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 traction when piping is installed on the aftercooler. Failure to follow this instruction may result in engine damage.

1.

NOTE: Install a new thermostat o-ring.

Reinstall the elements in reverse order.