Technical REplacing 1.9JTD stat

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Technical REplacing 1.9JTD stat

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Hi there,
After 4 cold winters in the multi im finally treating myself to a thermostat!

Is it wise to first flush out/descale whats in there for fear of it crudding up the new stat?
If so just any old product and where is best to drain from to ensure i get all the fluid out?

Cheers,
Marty
 
To be honest when I done mine a few years back I was amazed at how clean the old stat was and the block.
So I just refitted and filled!

However it wasnt as easy as that!!
There is a stupid heat exchanger in the way!!
 
Cheers..did you put in a new one?
Im sure i read (probably here) somewhere that crud etc in the coolant can cause them to start sticking soon after replacing if the cooling system is not flushed.
Marty.
 
Yes I put a new thermostat on with new antifreeze, but didn't flush anything out as mine was spotless, no rust no anything..
I suppose if yours looks cruddy then I would definitely flush it with clean water.
Just attach a hose and blast it thru!!
 
Changed my stat last night on jtd 115.
Pig of a job...the egr cooler shares a stud with the stat so that had to be pulled to one side. But to do that you have to unbolt the other bracket holding in the egr cooler...2 bolts 13 mm.. One is accessible enough the other is practically impossible to even see. To get the last bolt out you need to remove the complete egr.
The pipes going to the egr cooler need to be disconnected and they are quite inaccessible aswell.
There are also shims that are easily lost in the engine bay between these pipes and cooler.
The whole job took me 7 hours...
Car is warm now tho!
Marty.
 
I did mine last summer and can't remember having to cut bend or remove anything ???

Can remember having to replace the factory clamps with hose clamps and having a leak from the pipe that runs in front of the engine but that was about it.
 
Ya, that was a complete pig of a job!
In the end I think I remember cutting and bending one of the lugs of the egr cooler out of the way. Obviously it didn't go back on! One nut held it on fine.

You did the right thing let me tell ya!!
If i was doing it again id do what you did.

Theres 3 bolts holding that cooler in all...2 are more than adequaute...chances are your EGR is blanked anyway ;)

In case anyone is reading this with a view to doing the job.
Remove the airbox...then unbracket the turbo boost switch to give you more room.
The stat in itself is just bolted to the side of the block...however one of the studs is shared with the EGR cooler.
And unfortunately the nut you need to access to remove the stat is completely blocked by the bracket that holds the EGR cooler.
My suggestion would be to cut that bracket somehow...probably a small grinder is all youd get in there..

Then remove the stat and get on with the job.

Otherwise...youll have to find the other 2 bolts that hold the cooler in position at the back of the engine.
If you move along the cooler towards the back of the engine bay youll notice a tall bracket coming off it and bolted to the block just below the inlet manifold.
Using a small mirror and torch you should be able to find the 2nd bolt.
Both of mine were 13mm for the record.
To access it however its easiest to remove the complete EGR...and also a small bracket between the EGR and the inlet manifold(easy 1 10mm bolt) that holds a wiring loom or vac tubes i cant quite remember.

The EGR cooler is hardpiped to the exhaust manifold at one end and the EGR at the other end.(clamped in place...allen key and a jiggle to remove)

I uncoupled the EGR cooler at both ends... there are tiny shims/gaskets that easily fall out so be expecting them and make sure you put them back in.
In hindsight i may have gotten away without uncoupling it at the back end of the engine where it couples to the EGR..as with the EGR removed there is no longer anything holding it in position. I found this really difficult to reconnect so would have saved me a good hour...maybe more so have a think about it.

Best of luck.
Marty.
 
You did the right thing let me tell ya!!
If i was doing it again id do what you did.

Theres 3 bolts holding that cooler in all...2 are more than adequaute...chances are your EGR is blanked anyway ;)

In case anyone is reading this with a view to doing the job.
Remove the airbox...then unbracket the turbo boost switch to give you more room.
The stat in itself is just bolted to the side of the block...however one of the studs is shared with the EGR cooler.
And unfortunately the nut you need to access to remove the stat is completely blocked by the bracket that holds the EGR cooler.
My suggestion would be to cut that bracket somehow...probably a small grinder is all youd get in there..

Then remove the stat and get on with the job.

Otherwise...youll have to find the other 2 bolts that hold the cooler in position at the back of the engine.
If you move along the cooler towards the back of the engine bay youll notice a tall bracket coming off it and bolted to the block just below the inlet manifold.
Using a small mirror and torch you should be able to find the 2nd bolt.
Both of mine were 13mm for the record.
To access it however its easiest to remove the complete EGR...and also a small bracket between the EGR and the inlet manifold(easy 1 10mm bolt) that holds a wiring loom or vac tubes i cant quite remember.

The EGR cooler is hardpiped to the exhaust manifold at one end and the EGR at the other end.(clamped in place...allen key and a jiggle to remove)

I uncoupled the EGR cooler at both ends... there are tiny shims/gaskets that easily fall out so be expecting them and make sure you put them back in.
In hindsight i may have gotten away without uncoupling it at the back end of the engine where it couples to the EGR..as with the EGR removed there is no longer anything holding it in position. I found this really difficult to reconnect so would have saved me a good hour...maybe more so have a think about it.

Best of luck.
Marty.
Building on this Marty. Did this job yesterday without reading up first ...
Got into problems with her cooler sharing the stud.
Found workaround
a. Loosen 2 6mm Allen bolts on egr valve but do not take off pipe
B. Cut 8mm or so off f...ing stud.
C. Get clamp of inlet to egr cooler
D. Hack plastic bit of bottom of thermostat where 2 pipes share connection. Makes room to wiggle cooler off and out of way enough.
See photos with comments attached.

Still a pig of a job. Lots of new hose clips.
My multijet is running cold and mpg is high. Also if cold I think the dpf will not regen properly, if anything like bmws.
The top hose fix, with thermostat in may may have been a better option ... described on here in 2019 posts.
 

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Building on this Marty. Did this job yesterday without reading up first ...

Got into problems with her cooler sharing the stud.

Found workaround

a. Loosen 2 6mm Allen bolts on egr valve but do not take off pipe

B. Cut 8mm or so off f...ing stud.

C. Get clamp of inlet to egr cooler

D. Hack plastic bit of bottom of thermostat where 2 pipes share connection. Makes room to wiggle cooler off and out of way enough.

See photos with comments attached.



Still a pig of a job. Lots of new hose clips.

My multijet is running cold and mpg is high. Also if cold I think the dpf will not regen properly, if anything like bmws.

The top hose fix, with thermostat in may may have been a better option ... described on here in 2019 posts.



Pig of a job... think it took me a whole day that time, my back was broke after it. My multi is long gone I’m afraid, I miss it for sure, was the only car that made me smile, but don’t miss this kinda stuff!!
 
Funny you should say about your back ... found myself in pain and sitting on a stool that made it better. less stooping ... Your write up saved me the most back pain though. Ta
 
Finishing it off just now, realised I had released pipe off egr valve completely. Had to take 3 off 13mm bolts off the egr to get it to line up with the clamp ... pig.
Reason for post is I am not 100 % sure youcanleave the 6mm allen key bolts in clamp. I would defo try it with just loosening.

I clamped the filler bottle and drained a little off the rad. Used about 2.5 litres of fresh coolant. I only had 3 ... phew.
 
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