Thermostat: Service and Repair

Removing and installing coolant regulator








Preliminary Work

Warning:
Coolant is hazardous to health.
^ Risk of skin irritation.

- Wear protective gloves and goggles.

- In the event of contact with the skin or eyes, wash immediately with plenty of water.

1. Remove air cleaner housing.
2. Drain coolant.

Removing coolant regulator

Information
^ Collect emerging coolant in a suitable pan.

1. Remove spring clamp on the Henn coupling -1- and pull off coolant hose -2-.
2. Move coolant hose -2- out of the work area.





Coolant regulator flange

3. Unscrew two Torx screws (M6) -Arrows- on the vacuum line.
4. Pull line -1- off the vacuum pump. Lay the line aside to enable easy access to parts.
5. Remove retaining bracket -2-.





Vacuum pump line

6. Unscrew three Torx screws (M6) -Arrows- on the cylinder head cap.
7. Remove cover -1-.





Camshaft housing cover

8. Unscrew three Torx screws (M6) -Arrows- on the coolant flange.
9. Remove coolant regulator cover and seal.





Screws on coolant regulator cover

10. Remove coolant regulator using assembly aid assembly aid 9627.





Removing/fitting thermostat insert

Installing coolant regulator

1. Install coolant regulator using assembly aid assembly aid 9627.





Removing/fitting thermostat insert

Information
To facilitate assembly of coolant pipes and hoses, smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel.

2. Fit coolant regulator cover and new seal.
3. Position and tighten Torx screws (M6) -Arrows-. - Tightening torque: 10 Nm (7.5 ftlb.)





Screws on coolant regulator cover

4. Fit cap -1-with new O-ring.
5. Position and tighten Torx screws (M6) -Arrows-. - Tightening torque: 10 Nm (7.5 ftlb.)





Camshaft housing cover

6. Fit retaining bracket -2-. - Tightening torque: 10 Nm (7.5 ftlb.)
7. Place vacuum line -1- on vacuum pump flange.





Vacuum pump line

8. Position and tighten Torx screws (M6) -Arrows-. - Tightening torque: 10 Nm (7.5 ftlb.)
9. Place spring clamp on the Henn coupling -1-.

Information
^ Check Henn coupling O-rings and replace them if necessary.
^ Clean plug connection and coolant hoses before assembly.
^ Coat O-rings and coolant hoses with Kluberplus Gel (Part No. 000.043.205.93).
^ Remove stoppers before fitting the coolant lines and hoses.

Information
The coolant hoses must engage audibly when pushed into the flanges (Henn coupling).

10. Position coolant hose -2- with new O-ring and insert it into the coupling -1-.





Coolant regulator flange

Subsequent work

Warning:
Coolant is hazardous to health.
^ Risk of skin irritation.

- Wear protective gloves and goggles.

- In the event of contact with the skin or eyes, wash immediately with plenty of water.

1. Filling in coolant.
2. Install air cleaner housing.
3. Check cooling system.