Engine 1.8-I / 125 hp
Withdrawal
The thermostat is located in the exhaust pipe of the cylinder block behind the generator.
Remove the wire «masses» with battery.
Attention
- When the wires are disconnected from the battery terminals, the data on the recorded malfunctions are erased in the memory blocks of the control devices, therefore, before disconnecting the wires, it is necessary to contact the workshop to recall the malfunctions recorded in it. After connecting the wires to the battery terminals, it is necessary to activate and reprogram the power windows, as well as the position of the rear-view mirrors and seats.
- If the car has a radio with a code, then before disconnecting the wires from the terminals from the battery, check that there is a code to reactivate the receiver. Otherwise, it will be possible to put the radio receiver into operation only at a specialized station.
Drain the coolant from the cooling system.
Remove the power steering reservoir cover from the spring clips.
Remove the electrical connectors of the anti-lock braking system from the holder (ABS) (see fig. 3.14). Do not disconnect electrical connectors.
Lift up the electrical connector holder.
Unscrew and remove the air pipe connecting the front cross member and the air filter.
Remove the generator.
Unscrew the two bolts and remove the connecting pipe from the engine block (see fig. 3.15). Remove the thermostat together with the O-ring. When installing, a new O-ring must be used.
Check thermostat and replace if necessary.
Installation
Clear the area for installing the O-ring.
Lubricate the new O-ring with coolant and install it on the thermostat.
Install the thermostat in the cylinder head so that the bleeder valve is at the top.
Install the connecting pipe of the cooling system and screw on the bolts, tightening them with a torque of 15 Nm.
Install the generator.
Install the air pipe connecting the front cross member and the air filter.
Connect wire «masses» to the battery. Repeat the operations for memorizing the position of seats, mirrors, etc., as well as set the time on the clock and enter the code into the radio.
Attach the ABS electrical connectors to the holder.
Fix in spring clips a casing of a reservoir of the amplifier of a steering.
Pour coolant into the cooling system.
Start the engine and check the cooling system for leaks.
Engines 1.8-I/150 HP and 1.9-I / 110 hp
The thermostat is located in the water pump housing.
Drain the coolant Remove the two bolts securing the coolant hose to the bottom of the water pump and drain the coolant into a suitable container. Move the cooling system pipe with the hose connected to it to the side (see fig. 3.16).
Remove thermostat and o-ring. When installing the thermostat, a new O-ring must be used.
Check thermostat and replace if necessary.
Installation
Install the thermostat with a new O-ring.
Install the pipe and fix it with bolts, tightening them with a torque of 10 Nm.
Pour coolant into the cooling system.
Start the engine and check the cooling system for leaks.
V6 2.4-/2.8-I engines (165/193 HP)
The thermostat is located in the coolant hose in front of the engine block.
Drain the coolant Remove the V-ribbed belt. Loosen the toothed belt tension and remove it from the camshaft pulleys.
Attention. To protect the toothed belt from coolant, cover the toothed belt with polyethylene.
Unscrew the two bolts and remove the cooling system connecting pipe from the front of the cylinder block (see fig. 3.17).
Remove the O-ring and thermostat from the cylinder block. Check thermostat and replace if necessary.
Installation
Install the thermostat in the cylinder block so that the bleeder valve is at the top (see fig. 3.18).
Install the cooling system connecting pipe with a new sealing ring and screw in the bolts, tightening them with a torque of 10 Nm.
Install the toothed belt onto the camshaft pulleys.
Install poly V-belt.
Pour coolant into the cooling system.
Start the engine and check the cooling system for leaks.
Engine V6 2.5-I-TDI / 150 hp
Withdrawal
The thermostat is located in the coolant hose in front of the engine block.
Drain the coolant
Remove poly V-belt.
Remove the viscous radiator fan pulley bolt.
Unscrew the bolts of the radiator fan bracket with a viscous coupling and idler pulleys 1 and 2 (pic. 3.19).
Unscrew a bolt of fastening of the bottom casing of a gear belt 4 (pic. 3.19).
Turn the toothed belt tensioner clockwise with an 8mm socket wrench and lock it in the retracted position with a 2mm diameter pin (see fig. 3.20).
Pull the toothed belt on the tension roller in the direction of the arrow shown in Figure 3.21.
Attention. Do not remove the toothed belt from the tension roller, as otherwise, the belt may be removed from the remaining pulleys and you will have to perform installation operations.
Unscrew bolts 1-3 and remove the thermostat housing (pic. 3.21).
Remove the O-ring thermostat.
Check thermostat and replace if necessary.
Installation
Install the thermostat in the cylinder block so that the bleeder valve is at the top (see fig. 3.18).
Install a new sealing ring.
Install the thermostat housing and secure with screws. Apply a blocking compound to the threads of bolt 2, e.g. Loctite 243, (pic. 3.21). Screw in and tighten bolts 1-3 to 10 Nm.
Move the toothed belt in the opposite direction along the tension roller and remove the pin.
Adjust the toothed belt tension.
Install and bolt the radiator fan bracket with viscous coupling and idler pulleys and lower toothed belt guard (see fig. 3.19).
Install the V-ribbed belt and viscous radiator fan.
Thermostat check
Remove the thermostat.
Measure the length of the closed thermostat a (pic. 3.23).
A rough test of the thermostat’s performance can be carried out by hanging it on a thread in a glass vessel filled with water and heating the water to a boil, while the thermostat should not touch the walls of the vessel (see fig. 3.22).
Check the water temperature with a thermometer. The thermostat should begin to open at 87°C and fully open at 102°C. Otherwise, replace it.
The thermostat opening temperature is marked on the thermostat housing.
When the thermostat is heated to a temperature of 102°C, the length of the open thermostat b must be greater than the length of the closed thermostat a by 8 mm (see fig. 3.23).
A thermostat that does not close when the water cools should also be replaced.
Install thermostat.
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