195819 Removing and installing coolant regulator (thermostat)

WM 195819 Removing and installing coolant regulator (thermostat)

Preliminary work

1. Drain the cooling system. -> 193817 Draining and filling in coolant Service and Repair
2. Remove the throttle housing. -> 244219 Removing and installing throttle housing 244219 Removing and installing throttle housing
3. Remove the coolant pump. -> 195019 Removing and installing coolant pump Service and Repair

Information

Component overview





Thermostat housing and coolant regulator





Removing coolant regulator

CAUTION

Pointed or sharp objects

- Risk of cracks, pricks or cuts

-> Wear personal protective gear.

Removed water pump -1- and thermostat insert -2- =>





Thermostat insert installed

1. Release cable plug for thermostat insert using angled pointed-nose pliers between the crankcase and thermostat housing and pull it off. => Cable plug for thermostat -1-





Cable plug for thermostat





Pointed-nose pliers with cable plug

2. Remove thermostat insert using shop-made tool.
2.1. Use pointed-nose pliers to wrap a piece of wire or stiff electric cable through several spokes of the thermostat insert. Figure showing screwdriver => Secured electric cable.





Secured electric cable

2.2. Tie a knot in the wire or electric cable to prevent it from being pulled out.
2.3. Insert an assembly lever or a large screwdriver through the cable. => Secured electric cable
2.4. Pull the thermostat insert out of the crankcase completely using an inserted assembly lever or a large screwdriver. Support the assembly lever under the vibration balancer if necessary. => Secured electric cable Figure shows removed thermostat insert => Removed coolant regulator.





Removed coolant regulator

Installing coolant regulator

Information

Damaged thermostat inserts must be replaced.

Use water-soluble assembly gel "Kluberplus S06-100" with the number 000 043 205 93 (status 06/08) for the sealing rings on the thermostat insert. Dilute it 50:50 with water.
1. Replace the sealing rings on the thermostat insert and coat them lightly with "Kluberplus S06-100". Figure shows thermostat insert with disassembly cable. -1- Check that the sealing rings are fitted at the correct position (sealing rings must not be installed the wrong way round).





Removed thermostat insert

2. Push the thermostat insert through the opening in the crankcase and into the thermostat housing. When doing this, make sure that the cable connection is facing upwards.





Thermostat housing and coolant regulator





3. Check that the coolant regulator was fitted as far as it will go. You must not be able to feel any overhang or underhang between the coolant regulator and crankcase. The coolant regulator must be seated flush in the crankcase.





Transfer pipe/intake socket fully inserted

4. Connect cable plug to the thermostat insert.

Subsequent work

1. Fit the coolant pump. -> 195019 Removing and installing coolant pump Service and Repair
2. Fit the throttle housing. -> 244219 Removing and installing throttle housing 244219 Removing and installing throttle housing
3. Bleed and fill the cooling system. -> 193817 Draining and filling in coolant Service and Repair
4. After replacing the coolant regulator, erase the fault memory for engine control again if necessary (old adaptation values will be adapted to suit the new thermostat insert).