Thermostat housing (1.8 l diesel) — removal and installation

Special tool

Clamp removal/installation tool 303-397 (24-003)

Removal

All cars

1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.

2. 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.

3. Remove the air deflector.



4. Disconnect the charge air cooler inlet pipe.



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




6. Remove the charge air cooler.



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



Cars with diesel engine 75 hp or 90 hp.

8. Disconnect the electrical connector of the glow plug wire.



All cars


9. Disconnect the oil level dipstick and secure it to the side (75hp or 90hp diesel vehicle shown, similar for 115hp diesel vehicle).



10. Disconnect the coolant hose (vehicle with 75hp or 90hp diesel engine shown, similar for vehicle with 115hp diesel engine).



Cars with diesel engine 75 hp or 90 hp.

11. Disconnect the coolant hose.



12. Remove the thermostat housing. Discard the gasket as it is no longer needed.




Cars with 115 hp diesel engine.

13. Disconnect the plug connector of the inlet metering valve.



14. Disconnect the wiring harness from the thermostat housing and secure it to the side.



15. Remove the thermostat housing mounting bolts.



16. Disconnect the coolant hose and remove the thermostat housing. Discard the gasket as it is no longer needed.

Installation

All cars

1.

NOTE: Install a new thermostat housing gasket.

Install the elements back in place in reverse order.

Cars with diesel engine 75 hp or 90 hp.



Cars with 115 hp diesel engine.



All cars