Removing
1. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
2. On 1.9L DW series diesel engines, loosen the clip in the center of the engine cover and remove the screw on the right side. Remove the engine cover. On 2.0L diesel engines, turn the four plastic tabs 90°and remove the engine cover (pic. 4.2, a-e).
Pic. 4.2, a. On 1.9L diesel engines, remove the clips on the right side...
Pic. 4.2b....and on the top plane of the engine cover
Pic. 4.2, c....then remove the engine cover
Pic. 4.2, d. On 2.0L diesel engines, to release each lock, turn it 90°...
Pic. 4.2, e....and then remove the engine cover
3. Drain the coolant from the cooling system (see chapter 1A or 1B).
4. Remove the air filter assembly and intake air lines as described in chapter 4A, 4B or 4B.
5. Remove the bolts and carefully remove the thermostat housing cover to open the thermostat (pic. 4.5). Be careful not to deform the hose (-And) coolant connected to the cap. Keep in mind that the design of the thermostat housing varies depending on the type of engine, but the procedure for removing the thermostat is the same for each type.
Pic. 4.5. The location of the cover on the thermostat housing (marked with an arrow) (model with 1.4 l petrol engine)
6. On early models with a separate thermostat, remove the thermostat from the housing, noting how it is installed. Remove the O-ring (-A) (pic. 4.6).
Pic. 4.6. Removing the sealing ring from the thermostat flange
7. On later models where the thermostat is an integral part of the housing cover, remove the o-ring, release the clip, and remove the cover from the coolant hose.
Examination
8. A rough test of the thermostat can be done by hanging it from a piece of fishing line in a container filled with water. Heat the water by bringing it to a boil. The thermostat should open by the time the water boils. If it is not, replace it.
9. If you have a thermometer, you can determine the exact opening temperature of the thermostat. Compare this value with the opening temperature specified in «Specifications». The opening temperature must also be marked on the thermostat.
10. A thermostat that does not close as the water cools must be replaced.
Installation
11. Installation is carried out in the reverse order of removal, taking into account the following points: