Removing temperature sensor

• Remove expansion tank cap
• Raise the car.
• Remove lower splash guard.
• Position a container under engine drain cock, drain engine coolant.
• Close stopcock.
• Lower the car.

Only turbocharged (TC) engines

• Remove turbocharger (TC) /charge air cooler (CAC) and air cleaner (ACL) /turbocharger (TC) plastic hoses.
• Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
• Remove upper timing belt cover.
• Lift up the servo reservoir and place on top of engine.
• Remove the hose between the expansion tank and the radiator.
• Lift up expansion tank.
• Disconnect level sensor connectors.
• Place reservoir over engine.
• Remove screw to front camshaft belt cover.
• Disconnect sensor cables connectors.
• Disconnect hose for control module box air at the box.
• Hold the air hose to one side and pull up the front camshaft belt cover.
• Disconnect sensor wire connector
• Remove sensor wire cable duct screw.
• Remove thermostat housing with cable duct.
• Secure thermostat housing in a vise and remove sensor.

Note: Handle the thermostat housing carefully when securing in the vise.

Installing temperature sensor

• Install new sensor with new gasket. Tighten temperature sensor to 22 Nm.
• Ensure that the sensor cable is correctly routed in the thermostat housing and in cable duct.
• Install thermostat housing with new gasket. Tighten to 17 Nm .
• Install screw to cable duct. Tighten to 10 Nm .
• Put control module box air hose to one side and depress the front camshaft belt cover.
• Press the air hose into place in control module box.
• Install front camshaft belt cover screw. Tighten to 12 Nm .
• Install expansion tank.
• Secure the hose between expansion tank and the radiator in the expansion tank.
• Install the reservoir tank and check that the hoses lie correctly.
• Install upper camshaft belt cover.

Only turbocharged (TC) engines

• Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp.
• Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC).
• Tighten hose clamps.

Follow-up work
Function test
Fill coolant.
Install expansion tank cap.
Test drive the engine until the thermostat has opened.
If necessary top up the coolant.