TD6 '02 FFRR Thermostat Exchange (sort by title) |
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35 - EGR Cooler – 904 viewsEGR cooler removed and left to dangle on a coolant hose. Three allen bolts (6mm) release this.
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36 - EGR Manifold Pipe – 860 viewsEGR pipe from exhaust manifold removed. Require T45 torx to remove with some skinny extensions
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37 - You can now see the Thermostat – 1003 viewsAh the thermostat at last, but look stupid torx bolts!! Another trip to Halfords.The bolts are male T40's, so you require a female T40 socket (or E8 as Halfords called it). Disconnect the bottom and side hoses by undoing the spring clips and then pulling. Then undo the bolts. You might not be able to fully remove the bottom hose, but don't worry, it will come apart when you remove the 'stat.
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38 - The old one - doesn\'t look to be a problem? – 887 views
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39 - Thermostat housng exposed – 835 viewsClean off the mating face before fitting new thermostat
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40 - Refitting the bottom hose to the new thermostat – 778 viewsUse some WD40 to ease the press/clip fitting into place. might need a bit of huffing and puffing to get it completely into place.
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41 - There we are - now to fit everything back on – 736 viewsRefer to photo 26 onwards for refitting of various items, and for the most part a reversal of all undoing/removal procedures before then (engine covers etc)
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26 - Fixing/Undoing the EGR pipe to the exhaust manifold – 713 views
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27 - Valve thingy inside coolant rail – 745 viewsTake care with the prongs, they easily break off
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28 - The coolant rail attached to the EGR cooler – 705 views
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46 - Refill with Coolant – 681 viewsUndo and remove the three bleed screws: 1. Coolant Rail, 2. EGR Cooler, 3. Expansion tank. Start to refill with coolant. The coolant will start coming out of the bleed holes in the order above, so replace bleed screws as this happens. Do these up nice and tight! Start engine and bring to operating temperature. Hey the needle stays in the middle! My car needed a 20 mile run for the coolant to find its level, needed topping up again and then was OK.
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29 - Fixing /Undoing the Coolant rail – 673 views
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