2.2L Diesel

Clean the gasket sealing surfaces.

Fig 1: Thermostat Housing & Bolts
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Using a NEW gasket seals, install the thermostat housing (1a). Tighten the bolts (1b) to the proper SPECIFICATIONS .

Fig 2: EGR Tube Bolts
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Install the bolts (1) securing the EGR tubes to the thermostat housing and tighten to the proper SPECIFICATIONS .

Fig 3: Coolant Temperature Sensor Wire Harness Connector
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Connect the coolant temperature sensor wire harness connector wire harness connector (1).

Fig 4: Front Oxygen Sensor Wire Connector
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Attach the wire harness connector to the bracket and connect the front oxygen sensor wire harness connector (1).

Fig 5: Degas Hose, Upper Radiator Hose & Clamps
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Install the upper radiator hose (2) onto the thermostat housing and tighten the clamp.
Install the degas hose (1) onto the thermostat housing and tighten the clamp.

Fig 6: Clamp & Coolant Hose
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Install the coolant hose (1) and tighten the clamp.

Fig 7: Bolts & CAC Tube
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Using a NEW O-ring seal, install the left charge Air Cooler (CAC) tube (1b). Tighten the bolts (1a) to the proper (Torque Specifications).

Fig 8: Retaining Clip & Quick-Disconnect Fitting
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Connect the vacuum brake booster hose (1b) quick-disconnect fitting (1b) and close the retaining clip (1a).

Fig 9: Bolt
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Install the bolt securing the left CAC tube. Tighten the bolts to the proper TORQUE SPECIFICATIONS - DIESEL .
Fill the cooling system. Refer to STANDARD PROCEDURE .
Install the belly pan. Refer to BELLY PAN, INSTALLATION .
Install the engine cover. Refer to
Install the battery tray. Refer to BATTERY, INSTALLATION .
Run engine to operating temperature and check for leaks.