2.0L Diesel: Removal

1. Remove the battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
2. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
3. Remove the engine cover. .
4. Drain the cooling system. Refer to STANDARD PROCEDURE .

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5. Remove the bolt (1) securing the left Charge Air Cooler (CAC) tube.

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6. Open the retaining clip (1a) and disconnect the vacuum brake booster hose (1b) quick-disconnect fitting (1b).

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7. Remove the bolts (1a) and the CAC tube (1b).

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8. Loosen clamp and remove the coolant hose (1).

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9. Loosen the clamp and remove the degas hose (1) from the thermostat housing.
10. Loosen clamp and remove the upper radiator hose (2) from the thermostat housing.

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11. Disconnect the front oxygen sensor wire connector (1) and detach wire harness connector from the bracket.

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12. Disconnect the coolant temperature sensor wire harness connector wire harness connector (1).

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13. Remove the bolts (1) and the EGR tubes from the thermostat housing.

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14. Remove bolts (1a) and the thermostat housing assembly (1b).

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15. Remove and discard the gasket seals (1).

INSTALLATION 

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1. Install NEW  gasket seals (1).

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2. Install the thermostat housing (1a). Tighten the bolts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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3. Install the bolts (1) securing the EGR tubes to the thermostat housing and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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4. Connect the coolant temperature sensor wire harness connector wire harness connector (1).

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5. Attach the wire harness connector to the bracket and connect the front oxygen sensor wire connector (1).

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6. Install the upper radiator hose (2) onto the thermostat housing and tighten the clamp.
7. Install the degas hose (1) onto the thermostat housing and tighten the clamp.

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8. Install the coolant hose (1) and tighten the clamp.

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9. Using a NEW  O-ring seal, install the left charge Air Cooler (CAC) tube (1b). Tighten the bolts (1a) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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10. Connect the vacuum brake booster hose (1b) quick-disconnect fitting (1b) and close the retaining clip (1a).

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11. Install the bolt securing the left CAC tube. Tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS - DIESEL  .
12. Fill the cooling system. Refer to STANDARD PROCEDURE .
13. Install the engine cover. .
14. Install the battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
15. Run engine to operating temperature and check for leaks.