2. Engine\Cooling system Adjustment/Replacement - Ther...

Thermostat, V6

Warning

Take care if the car is warm. The coolant is hot and

there is also a risk of burning yourself on the exhaust
manifold.

To remove

1. Open the cap on the expansion tank and release the pressure.

2. Raise the car.

3. Remove the lower front cover.

4. Drain the coolant from the radiator.

5. Lower the car to the floor.

6.
Remove the upper engine cover.

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7. Remove the upper intake manifold.

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8. Remove the middle intake manifold.

9. Remove the lower intake manifold.

10. Remove the mass air flow sensor and hose.

11. Detach the turbo's intake pipe and move it towards the charge air cooler. Also
detach the turbo bypass pipe and the connection to the crankcase breather pipe.

12. Remove the dipstick and the pipe going to the thermostat.

13.

Remove the thermostat and thermostat housing.

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To fit

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Warning

Be careful if the car is warm. The coolant is hot and

there is a risk of burns from the intake manifold.

1. Check and clean the sealing surfaces.

2. Fit a new O-ring to the thermostat and its connecting pipe. Coat the O-ring with a
little non-acidic vaseline to facilitate assembly.

3. Fit the thermostat and its connecting pipe.

Tightening torques:

Thermostat: 20 Nm (14.7 lbf ft)

4. Fit the dipstick.

5.
Fit the turbo intake pipe. Also fit the turbo bypass pipe and the crankcase breather
pipe connection.

Tightening torques:

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Turbo/intake pipe, V-clamp: 3 Nm (2.2 lbf ft)

Bypass pipe/intake pipe, bolt: 8 Nm (5.9 lbf ft)

Bypass pipe, hose clip: 8 Nm (5.9 lbf ft)

Crankcase breather pipe: 24 Nm (17.7 lbf ft)

6. Fit the mass air flow sensor and hose.

7. Fit the lower intake manifold. Check the O-ring and coat it with non-acidic vaseline.

Tightening torque: 20 Nm (14.7 lbf ft).

8. Fit the middle intake manifold.

Tightening torque: 20 Nm (14.7 lbf ft).

9. Fit the upper intake manifold, using a new gasket.

Tightening torque: 20 Nm (14.7 lbf ft).

10. Fill with coolant. Do not forget to close the drain plug on the radiator first. Refer to
Coolant for mixtures.

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11. Vent the cooling system as follows:

Fill the system to the MAX level, close the expansion tank filler cap, start the engine
and warm it up at varying speeds until the radiator fan starts. Open the expansion
tank filler cap and fill up again to the MAX level. Close the cap and run the engine at
varying throttle openings until the radiator fan has started three more times. Switch
off the engine and top up as necessary to the MAX level.

Note
The A/C should be OFF.

12. Raise the car.

13. Check for any leakage.

14. Fit the lower front cover.

15. Lower the car to the floor.

16.

Fit the upper engine cover.

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