2. Before removing the thermostat, drain some of the coolant (see section 3).
Engine 1.3
3. Unscrew the mounting bolts and remove the camshaft belt cover. Disconnect the upper radiator hose from the engine - this is where the thermostat housing is located.
4. Unscrew the 2 mounting bolts and remove the housing to get to the thermostat located in the cylinder head. Remove the thermostat, paying attention to how it was installed (see photos).
Photo 8.4A. Removing the thermostat housing (engine 1.3).
Photo 8.4B. Removing Thermostat with O-Ring (engine 1.3).
5. To check the operation of the thermostat, lower it on a string into boiling water. When immersed in boiling water, the thermostat should open. Pull out the thermostat and check if it closes. This is a fairly simple function test to identify a faulty thermostat. You can use a thermometer to check the opening temperature of the thermostat (see Specifications), however, you can no longer check the full opening temperature, because it exceeds the boiling point of water. When replacing a thermostat, check that it matches the temperature characteristics of your model (see photo).
Photo 8.5. The opening temperature is indicated on the thermostat.
6. Install the thermostat in the reverse order. Replace the thermostat O-ring and reinstall it correctly (see photos).
Photo 8.6A. Installing a new O-ring on the thermostat.
Photo 8.6B. Installing the thermostat on the cylinder head (engine 1.3).
7. Tighten the thermostat housing bolts to the required torque and add coolant to the system.
Engines 1.6 and 1.8
8. The procedure for removing, checking and installing the thermostat on these engines is basically similar to that given for the 1.3 engine, with the difference that the thermostat is located on the outside of the camshaft belt cover, and access to it is much easier (see photos).
Photo 8.8. Thermostat housing and cover (engine 1.6).
9. On carburetor models, remove the air cleaner. Drain the coolant and remove the bolts securing the thermostat housing cover.
10. Remove the thermostat and, if necessary, check its operation (see paragraph 5).
11. When installing a thermostat, always replace the thermostat housing cover seal.
12. If it is necessary to remove the thermostat housing, first remove the camshaft timing belt and the rear belt guard (see chapter 1).
13. Disconnect all hoses from the thermostat housing, noting their relative position.
14. Unscrew the 2 bolts securing the thermostat housing and remove it. Remove the O-ring.
15. Install the thermostat housing in the reverse order. Install a new O-ring and tighten the housing bolts to the correct torque.
16. Pour liquid into the cooling system (see section 6).
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