Withdrawal
Cars with a gasoline engine
1. Drain the coolant (see relevant chapter).
2. Disconnect the coolant hoses from the thermostat housing.
3. Unscrew the bolts (see arrows in illustration) and remove the thermostat housing.
4.3. Unscrew the bolts (see arrows) and remove the thermostat housing
4. Remove the thermostat mounting bracket using a mandrel, catalog number 3265 (see arrow in illustration), and then carefully remove the thermostat from the housing.
4.4. Remove the thermostat mounting bracket using a mandrel, catalog number 3265 (see arrow)
Diesel vehicles
5. Drain the coolant (see relevant chapter).
6. Remove the front bumper (see relevant chapter).
7. Set the upper cross member of the front end to the service position.
8. Remove the ribbed accessory drive belt (see relevant chapter).
9. Unscrew the bolts (see arrows in illustration) and remove the right side of the rear timing cover.
4.9. Unscrew the bolts (see arrows) and remove the right side of the rear timing cover. Diesel vehicles
10. Remove the cap from the oil filler neck.
11. Turn the crankshaft in the direction of engine rotation by the central pinion bolt until the inscription appears in the oil filler hole «FROM» (top dead center) on the camshaft (see illustration).
4.11 Turn the crankshaft in the direction of engine rotation by the central bolt of the drive gear until the inscription appears in the oil filler hole «FROM» (top dead center) on the camshaft. Diesel vehicles
12. Unscrew a carving stopper on the block of cylinders approximately at the level of the average cylinder.
13. Replace the plug with a locking pin, catalog number 3242 (see illustration). Make sure that the pin goes into the hole on the cheek of the crankshaft and stops the shaft.
4.13. Replace the plug with a locking pin, part number 3242. Vehicles with a diesel engine
14. Unscrew the bolts 1 and remove the vibration damper from the injection pump gear (see illustration).
4.14. Unscrew the bolts 1 and remove the vibration damper from the injection pump gear. Diesel vehicles
Attention! Do not unscrew nut 2 (see illustration 4.14), as this can lead to a violation of the basic adjustment of the injection pump. Subsequent adjustment of the injection pump is not possible even in a workshop.
15. Mark with chalk, marker or paint the direction of travel of the injection pump drive timing belt if it is to be reinstalled. Failure to follow the previous course of the toothed belt during its further operation leads to its damage or rupture.
16. Loosen the tension of the injection pump drive timing belt by turning the roller with a socket wrench, and remove the injection pump drive timing belt from the camshaft gear (see illustration).
4.16. Loosen the tension of the injection pump drive timing belt. Diesel vehicles
17. Remove the three bolts (see arrows in illustration) and remove the gear wheel 1 of the injection pump drive.
4.17. Remove three screws (see arrows) and remove the gear wheel 1 of the injection pump drive. Diesel vehicles
18. Unscrew eight bolts 1 and remove the accessory drive belt pulley from the crankshaft. The central bolt 2 is attached to the crankshaft, the timing gear is attached, therefore, when removing the belt pulley, it is not necessary to unscrew the central bolt (see illustration).
4.18. Unscrew eight bolts 1 and remove the accessory drive belt pulley from the crankshaft. The central bolt 2 does not need to be unscrewed. Diesel vehicles
19. Remove the lower part 4 of the protective cover of the timing drive (see illustration).
4.19. Remove the lower part 4 of the protective cover of the timing gear drive. Diesel vehicles
20. Remove bolts 1, 2 and 3 and remove the viscous fan mounting bracket (see illustration 4.19). On the same bracket are guide rollers.
21. Slowly turn the toothed belt tensioner pulley with an 8 mm socket wrench to the right (see arrow in illustration) so that the tensioner plunger enters the body and the holes on the body and plunger are aligned. Insert a suitable pin into the aligned holes, for example, the pin, the catalog number of which is T40011, thereby fixing the plunger in the tensioner body.
4.21. Slowly turn the toothed belt tensioner with an 8 mm Allen key to the right (see arrow) so that the tensioner plunger enters the body and the holes on the body and plunger are aligned. Insert the T40011 pin into the aligned holes. Diesel vehicles
Attention! The timing belt tensioner has an oil-filled plunger and therefore the plunger should be pressed into the tensioner body slowly with uniform force. Excessive force may damage the idler pulley.
22. Feed the toothed belt on the guide roller a little forward (see arrow in illustration).
4.22. Feed the toothed belt slightly forward on the guide roller (see arrow). Diesel vehicles
Attention! Do not allow the belt to slip off the guide roller, because in this case the timing belt will have to be laid and adjusted completely. Failure to do so may result in severe engine damage.
23. Disconnect the coolant hose from the thermostat housing.
24. Unscrew the bolts 1-3 fastening and remove the thermostat housing (see illustration 4.22).
25. Carefully remove the thermostat from the housing along with the O-ring.
Installation
The thermostat is installed in the reverse order of removal.
26. Clean the contact surfaces, replace the old thermostat o-ring with a new one.
27. Cars with a gasoline engine. Install the thermostat so that the vent valve is at the top (see arrow in illustration), bracket 2 fastenings - under pin 1.
4.27. Install the thermostat so that the vent valve is at the top (see arrow), bracket 2 fastenings - under pin 1. Cars with a gasoline engine
28. Cars with a diesel engine. Install the thermostat so that the vent valve is at the top (see arrow in illustration).
4.28. Install the thermostat so that the vent valve is at the top (see arrow). Diesel vehicles
29. Install a new thermostat o-ring. The working surface of the ring must face the thermostat housing.
30. Bolt the thermostat housing after lubricating the threads of bolts 2 and 3 (see illustration 4.22) protective lubricant. The tightening torque of the thermostat housing bolts is 10 Nm.
31. Move the toothed belt on the guide roller to its original position (see arrow in illustration 4.22).
Attention! If the toothed belt has completely slipped when it was displaced on the roller, then the belt must be laid and adjusted.
32. Turn the tension roller with a socket wrench 8 mm to the right (see arrow in illustration) so that you can remove the pin T40011, which fixed the tensioner plunger.
4.32. Turn the tension roller with a socket wrench 8 mm to the right (see arrow) - so that you can remove the pin T40011, which fixed the tensioner plunger
33. Tension the toothed belt by turning the eccentric of the tension roller with a torque wrench with a force of 15 Nm counterclockwise and in this position of the eccentric tighten the roller fastening bolt (see illustration).
4.33. Tension the toothed belt by turning the tensioner eccentric with a torque wrench with a force of 15 Nm counterclockwise
34. Replace and secure with bolts 1-4 (see illustration 4.19) viscous fan mounting bracket. Tightening torques: bolt 1 - 45 Nm, bolt 2 - 10 Nm, bolt 3 - 22 Nm, bolt 4 - 10 Nm.
Thermostat check
35. Remove the thermostat.
36. Heat the thermostat by lowering it into a container of water. In this case, the thermostat should not touch the walls of the container and should be completely immersed in water. Check the water temperature with an appropriate thermometer.
The beginning of the thermostat opening - at a water temperature of approximately + 87°C; termination of the opening of the thermostat - when the water is heated to about + 102°C. The opening stroke of the thermostat must be at least 8 mm.
37. Install thermostat.
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