Procedures

1088C30 THERMOSTAT UNIT - R+R

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V

Engines: 2.0 JTD 8V

Removing

- Position the vehicle on the lift. Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1048A21 See in Op. 1048A50 Op. 1048B16 PIPES AND/OR ELBOW BETWEEN TURBOCHARGER AND THROTTLE CASING - R.R. Op. 1048B12 RIGID PIPE CARRYING AIR BETWEEN TURBOCHARGER AND INLET MANIFOLD - R+R- Position a suitable container for collecting the coolant.1. Disconnect the upper hose (1a) and the lower hose (1b) from the thermostat.

Engines: 2.0 JTD 8V

1. Using suitable pliers, open the bands retaining the coolant supply and return pipes to the engine oil heat exchanger.

	Description	Code	Function
.	Caliper	1.831.138.000	Band opening

Engines: 2.0 JTD 8V

1. Undo the bolts fixing the fuel return manifold mounting bracket.2. Release the return manifold from the housing and place it outside of the work area.

Engines: 2.0 JTD 8V

1. Disconnect the electrical connection for the water temperature sensor.

	Description	Connector
1	Engine coolant temperature sensor/sender unit	K036

2. Disconnect the recirculation pipe.3. Disconnect the water pipe to the exhaust gas heat exchanger from the thermostat.

Engines: 2.0 JTD 8V

1. Undo the fixing nuts.2. Remove the turbocharger air outlet rigid pipe mounting bracket.

Engines: 2.0 JTD 8V

1. Undo the fixing nuts and bolts.2. Remove the thermostat unit from the housing in the cylinder head.

Engines: 2.0 JTD 8V

Refitting

Removing

- Fit the thermostat in the housing in the cylinderhead checking that it is correctly engaged with the rigid coolant pipe and tighten the fixing nuts and bolts to torque.

	Value - daNm	Fastening	Component	Ø
.	2	bolt	CONTAINER GR. THERMOSTAT	-

	Value - daNm	Fastening	Component	Ø
.	2	Nut	CONTAINER GR. THERMOSTAT	-

- Fit the turbocharger rigid air outlet pipe mounting bracket and tighten the fixing nuts.- Connect the water pipe to the exhaust gas heat exchanger to the thermostat.- Connect the recirculation pipe.- Connect the electrical connection for the water temperature sensor.

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

- Place the return manifold in position and tighten the fixing bolts.- Using suitable pliers, close the bands retaining the coolant supply and return pipes to the engine oil heat exchanger.

	Description	Code	Function
.	Caliper	1.831.138.000	Band opening

- Connect the upper hose and the lower hose to the thermostat. Op. 1048B12 RIGID PIPE CARRYING AIR BETWEEN TURBOCHARGER AND INLET MANIFOLD - R+R Op. 1048B16 PIPES AND/OR ELBOW BETWEEN TURBOCHARGER AND THROTTLE CASING - R.R. See in Op. 1048A50 See in Op. 1048A21 Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 7055B54 UNDER-ENGINE GUARD - R R- Remove the vehicle from the lift.

Engines: 2.3 JTD 16V

Removing

Refitting

Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1088D181. Undo the upper and side bolts securing the timing belt protective cover.

Engines: 2.3 JTD 16V

1. Disconnect thermostat electrical connections (1a) and (1b).

	Description	Connector
1a	Coolant temperature sending unit (for instrument panel)	K035

	Description	Connector
1b	Engine coolant temperature sensor/sender unit	K036

2. Undo the bolts securing the thermostat to the cylinder head.3. Remove the thermostat unit from the cylinder head.

Engines: 2.3 JTD 16V

Refitting

Removing

- Change the thermostat o-ring.- Fit the thermostat unit in its seat on the cylinder head.- Tighten the bolts securing the thermostat to the cylinder head to torque.

	Value - daNm	Fastening	Component	Ø
.	-	Bolts	THERMOSTAT	-

- Connect the electrical connections for the thermostat.

	Description	Connector
.	Coolant temperature sending unit (for instrument panel)	K035

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

- Tighten the upper and side bolts securing the timing belt protective cover. See in Op. 1088D18 Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T21 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 7055B54 UNDER-ENGINE GUARD - R R

Engines: 2.0 16V

Removing

Refitting

- Disconnect the negative battery terminal. See in Op. 1048A21 Op. 1048A39 SLEEVE FROM AIR CLEANER TO RIGID PIPE - R R Op. 5510C10 IGNITION COIL/S - R+R Op. 7055B54 UNDER-ENGINE GUARD - R R- Position a suitable container for collecting the coolant.- Lower the vehicle.1. Disconnect the electrical connection for the cam angle sensor.2. Disconnect the electrical connection for the engine coolant temperature sensor.3. Remove the band (3a) and relese the coolant oulet hose from the thermostat (3b).4. Remove the band (4a) and release the heater coolant supply pipe (4b).5. Undo the retaining bolts (5a) and remove the thermostat unit (5b).

Engines: 2.0 16V

Refitting

Removing

- Fit the thermostat unit in place.- Tighten the fixing bolts to the recommended torque.- Fit the thermostat unit inlet and outlet hoses and restore the bands removed previously.- Connect the electrical connection for the cam angle sensor.- Connect the engine coolant temperature sensor electrical connection. Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1048A21 Op. 1048A39 SLEEVE FROM AIR CLEANER TO RIGID PIPE - R R Op. 5510C10 IGNITION COIL/S - R+R Op. 0010T21 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY- Connect the negative battery terminal.