Removal procedure
Attention! To prevent personal injury, do not remove the expansion tank cap on a hot engine and radiator as the heat pressurizes the system. Hot liquid and steam can escape under high pressure.
1. Drain the coolant. follow the paragraph «Draining and recharging the cooling system» in this section.
2. Remove the decorative cover. See Section 1B, "Engine mechanical system - 2.0 Diesel".
3. Remove the charge air cooler inlet hose from the charge air cooler. See Section 1B, "Engine mechanical system - 2.0 Diesel".
4. Disconnect the upper radiator hose from the thermostat housing.
5. Remove the bolt securing the fuel injection pump to the rail feed tube.
6. Remove the thermostat housing.
7. Remove thermostat with gasket.
Installation procedure
1. Install the thermostat with a new gasket.
2. Install the thermostat housing.
3. Install the fuel line to common rail bolt.
Tighten
Tighten the thermostat housing bolts to 23 Nm (17 lb-in).
Tighten the bolt securing the fuel line to the common fuel rail to 10 Nm (88.5 lb-in).
