Coolant Outlet: Service and Repair

Removal
1. Open the engine compartment and fit paintwork protection sheets.
2. Drain the radiator. Retain the coolant drain tray in position to catch any spillage when removing the outlet pipe.





3. Disconnect the top hose and breather pipe from the coolant outlet pipe.
Release and reposition the hose clip, and disconnect the top hose.
Release and disconnect the breather pipe quick fit connector.
Disconnect the multi-plug from the temperature sensor and unscrew the sensor from the outlet pipe.
Release and reposition the hose clip along the bypass hose.





4. Disconnect the bottom hose from the thermostat housing.
Release and reposition the hose clip along the hose.
Disconnect the bottom hose.





5. Disconnect the coolant outlet pipe from the cylinder heads.
Remove the four bolts which secure the outlet pipe.
Remove the outlet pipe from the bypass hose and from the cylinder heads (still connected to the heater hose).
6. Release and reposition the clip which secures the heater hose to the outlet pipe and disconnect the hose. Remove the outlet pipe.





7. Remove the thermostat from the outlet pipe.
Remove the three bolts which secure the thermostat cover to the outlet pipe.
Remove the thermostat cover, the thermostat and the seal from the outlet pipe. Discard the seal.
8. Remove and discard the sealing rings from the outlet pipe grooves.

Installation
1. Installation is the reverse of the removal procedure.
Use new sealing rings on the coolant outlet pipe and thermostat housing.
The thermostat ball valve must locate in the recess in the cover.
2. Tighten the coolant outlet pipe bolts to 8-12 Nm. If replacing the coolant temperature sensor, tighten to 15-19 Nm.
3. Refill the cooling system as described under Cooling System; Service and Repair.