Note: A new sealing washer must be used when installing the sensor.
Removal
1. The thermostatic sensor is located on the side of the thermostat housing/fuel filter.
2. For easier access on 1.9L models, remove the air distribution housing as described in paragraph 3. If necessary, also remove the air intake duct and disconnect the vent hose from the oil filler pipe. For more information, please refer to the relevant paragraphs in this chapter.
3. Drain the coolant from the cooling system as described in chapter 1B.
4. Loosen the clamp screw or nut (whichever is applicable) and disconnect the high idle speed cable end from the cable on the high idle speed lever of the high pressure fuel pump (figure 4.4, a, b).
Figure 4.4, a. High idle speed cable end clamp nut (marked with an arrow) (lucas pump)
Figure 4.4, b. Loosening the high idle speed cable end clamp screw (marked with an arrow) (bosch pump)
5. Remove the cable from the adjusting screw located in the bracket on the high pressure fuel pump (figure 4.5).
Figure 4.5. Removing the high idle speed cable from the adjusting screw (bosch pump)
6. Using a suitable open-end wrench, unscrew the thermostatic sensor from the thermostat housing/fuel filter and remove the sensor together with the cable (figure 4.6). Remove the sealing washer if applicable.
Figure 4.6. High idle speed thermostat sensor (marked with an arrow)
Installation
7. If sealant was used instead of a gasket for the original installation, carefully remove all traces of the "old" sealant from the sensor and housing. Make sure that no traces of sealant remain inside the coolant passages in the housing.
8. Install the sensor using suitable sealant or a new washer (whichever is applicable), and tighten it securely.
9. Insert the adjusting screw into the bracket on the high pressure fuel pump and tighten the lock nut by hand.
10. Pass the cable through the high idle speed lever and install the end cap onto the cable, but do not tighten the clamp screw or nut (whichever is applicable).
11. Adjust the cable as described in the following paragraphs.
Adjustment
12. With the engine cold, fully depress the high idle speed lever toward the flywheel end of the engine. Tighten the clamp screw or nut to hold the cable end in contact with the lever.
13. Adjust the screw so that the high idle speed lever touches the corresponding stop, and then tighten the lock nut.
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14. Measure the length of the open section of the cable.
15. Install the components removed to gain access to the sensor (see the relevant paragraphs of this chapter).
16. Fill the cooling system as described in chapter 1B, and allow the engine to run until it reaches normal operating temperature.
17. Check that the high idle speed cable has slack. If not, the sensor may be faulty.
18. With the engine warm, check the cable for approximately 0.5-1 mm of play on the Lucas pump and 5-6 mm of play on the Bosch pump. This indicates that the thermostatic sensor is working properly.
19. Make sure that the engine's crankshaft speed increases when the idling boost lever is pressed in the direction of the engine end where the flywheel is located. When the lever is moved all the way to the stop, the high idle speed should correspond to the specified value (for detailed information on adjusting the high idle speed, refer to paragraph 9).
20. Stop the engine.