Attention! If the engine overheats after a short mileage, the cause may be limescale deposits clogging the radiator, or a broken V-belt of the water pump drive.
Removal
1. Disconnect the negative (-) battery terminal.
Warning! This will delete data from the memory devices, such as the radio receiver security code. Before disconnecting the battery, read the recommendations in the chapter "Battery - Removal and Installation".
2. Drain the coolant into a suitable container.
3. Remove cover 1 of the thermostat housing by unscrewing the mounting bolts (see illustrations 6.3 and 6.3a).
6.3 Remove the thermostat housing cover 1 by unscrewing the mounting bolts. The illustration shows a 1.4-/1.6-liter petrol engine (K7J/K7M)
6.3a Remove the cover 2 of the thermostat housing by unscrewing the mounting bolts. Petrol engine with a volume of 2.0 liters and diesel engine with a volume of 1.9 liters
4. Record the installation position of thermostat 11 in the coolant pipe and remove it (see illustration).
6.4 Note the installation position of thermostat 11 in the coolant pipe and remove it. The illustration shows a diesel engine
Examination
5. Measure the height of the thermostat and record it as value a (see illustration).
6.5 Measure the height of the thermostat and record it as value a
6. Heat the thermostat in a container with water. The thermostat should not touch the walls of the container and should be completely immersed in water. Check the water temperature with an appropriate thermometer (see illustration).
6.6 Heat the thermostat in a container of water
Once the water temperature reaches approximately +89°C, the thermostat valve will begin to open.
The greatest stroke of the thermostat valve occurs at a temperature of approximately +101°C. At this water temperature, the valve should open completely. This means that its stroke should be at least 7.5 mm. To determine the stroke of the thermostat valve, it is necessary to subtract the value a from the value b (see illustration 6.5).
Attention! Since the thermostat opens completely when the water temperature exceeds its boiling point, the data provided should be considered as approximate.
7. Make sure that the thermostat valve closes when cooling down. If not, replace the thermostat.
Installation
8. Install the thermostat into the outlet pipe.
9. Cars with a 1.4-/1.6-liter gasoline engine (K7J/K7M). Clean the sealing surfaces on the cylinder head and thermostat housing. Apply sealant to these surfaces "LOCTITE 518" the layer of sealant H should be between 0.6 and 1.0 mm and it should be applied as shown in the illustration.
6.9 Apply sealant to these surfaces "LOCTITE 518". The layer of sealant H should be within the range of 0.6 to 1.0 mm 5
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10. Cars with 2.0 litre petrol engine and 1.9 litre diesel engine: Secure the thermostat cover by replacing its old rubber gasket with a new one.
11. Connect the negative (-) terminal of the battery cable to the negative terminal.
12. Set the clock.
13. Enter the code into the radio receiver if necessary.
14. Fill the coolant and bleed air from the cooling system.
