Hi All,


I have followed the instructions on the fiat workshop manual and viewed most of the other threads on the forum, but have not come across my issue mentioned.

The issue I have is that once all the pipework is out the way, the instructions say to undo 2 M8 bolts and remove the thermostat housing.

However I have an M8 Bolt in the top, but below there is no M8 Bolt. The only fixing below is a 10mm nut which holds the heat exchanger bracket. There is no movement in the heat exchanger, to get to the nut holding the thermostat housing to the block behind the bracket.

Surely I don't have to remove the heat exchanger from the exhaust manifold and egr to get the flipping thermostat off.

Has anyone come across this layout, and if so how did you get this resolved.

All suggestions welcome.

Thanks.

I had the same issue on my GP. No other way around it, the egr heat exchanger needs to be moved to one side. I did this by disconnecting the egr inlet and outlet from the exchanger, laving it free to move gently away from the engine block enough to get to the bolts holding the thermostat on.

Needs must i'm afraid

Brickfoot, Thanks for the reply and the heads up on your experience,

I have taken the egr off and there is no extra movement of the heat exchanger at the bracket. Do I have to undo the exhaust end of the heat exchanger?,

Also do you know what the purpose of the clamps either side othe the heat exchanger body. I have slackened these off, but again hasn't provided any additional wiggle room.

If it's the same as the JTD 8 valve engine in the Stilo, you need to remove both bolts holding the heat exchanger, and both clamps holding the corrugated pipes to the heat exchanger.

The rear bolt is difficult to get to. There may be circular metal ring gaskets in between the heat exchanger and the corrugated pipes.
.

Hi Davren,
Thanks for the reply and pic, that is really helpful.
Didn't see the heat exchanger bolt at the top back if its there is not undone. Gonna investigate now.

Update.

I found the top rear bolt (13mm hex head), took it out, slackened off fully both clamps. The clamp and corrugated pipe on the egr side rotate, on the heat exchanger. The clamp cannot rotate on the exhaust side and neither can the corrugated pipe as it is still fixed to the exhaust manifold. There is absolutely no movement of the heat exchange canister.

With the top rear bolt removed, is the bracket supposed to move side to side or up and down?
Do I need to remove the throttle body to get this movement?

Thanks again.

Re: Thermostat replacement 1.9 8v - Advice required - Now solved.

Well I finally managed to get the thermostat changed.

Thanks Devran for pointing me in the direction of the rear top bolt for the heat exchanger.
What I had to do was remove egr and the throttle body after I had no joy with getting wiggle room from removing the top bolt. With the throttle body out of the way, I found another bolt at the rear. Removing this bolt allowed me to move the heat exchanger bracket enough to get at the lower thermostat stud. See picture of heat exchanger with L bracket.

Thanks again for the suggestions etc.

Re: Thermostat replacement 1.9 8v - Advice required - Now solved.

I don't remember seeing a lower rear bolt on mine. Perhaps a previous owner had left it out.
.