1.6L Diesel: Removal

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

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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 the clamp and remove the coolant hose (1) from the thermostat housing.
9. Loosen the clamp and remove the radiator hose (2) from the thermostat housing.
10. Remove bolts (3a) and the thermostat housing (3b).

INSTALLATION 

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1. Using a NEW  gasket, install the thermostat housing (1a) Tighten the bolts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
2. Install the radiator hose (2) onto the thermostat housing and tighten the clamp.
3. Install the coolant hose (3) onto the thermostat housing and tighten the clamp.

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

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

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6. Install the bolt (1) securing the left CAC tube and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
7. Fill the cooling system. Refer to STANDARD PROCEDURE .
8. Install the engine cover. .
9. Install the battery.. BATTERY, REMOVAL AND INSTALLATIONBATTERY, SUPPLEMENTAL, REMOVAL AND INSTALLATION .
10. Run engine to operating temperature and check for leaks.