Thermostat Housing Assembly Replacement Opel Agila B

Remove

1. 1. Disconnect battery negative lead • Release nut
2. 2. Remove cap from coolant expansion tank
3. 3. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

4. 4. Drain cooling system • Place collecting container below • Open radiator drain plug • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
5. 5. Lower vehicle
6. 6. Disconnect harness connector (3) from mass air flow (MAF) meter
7. 7. Release cover (2) from air cleaner assembly • Release 4x screw, then move to one side
8. 8. Remove air cleaner element from air cleaner assembly
9. 9. Release outlet hose (1) from air cleaner assembly • Release clip
10. 10. Release harness for mass air flow meter from air cleaner assembly • Release clip
11. 11. Remove air cleaner assembly from battery tray and upper front panel • Remove 2x bolt (4) • Pull up to release 2x locator from battery tray

12. 12. Remove heater outlet pipe with turbo pipe assembly from EGR cooler (1) • Release 5x clip, 3x bolt

13. 13. Disconnect harness connector (2) from engine control temperature (ECT) sensor (1) • Release lock
14. 14. Remove ECT sensor from thermostat housing assembly

15. 15. Disconnect upper radiator hose from thermostat housing • Release clip • Install 2x new blanking plug
16. 16. Disconnect outlet hose for coolant expansion tank from thermostat housing • Release clip • Install 2x new blanking plug • Move hose to one side
17. 17. Remove 2x coolant hose from thermostat housing • Release 2x clip (1) • Install 4x new blanking plug

18. 18. Remove thermostat housing from cylinder head • Remove 2x bolt (1, 2) and rubber seal

Install

19. 19. Clean mating surface of cylinder head for new thermostat housing
20. 20. Install new rubber seal to thermostat housing • Apply suitable lubricant to seal, then push on
21. 21. Install thermostat housing to cylinder head • Install 2x bolt (1, 2) 28 Nm

22. 22. Install 2x coolant hose to thermostat housing • Secure 2x new clip (1) • Remove 4x blanking plug

23. 23. Connect outlet hose for coolant expansion tank to thermostat housing • Remove 2x blanking plug • Secure clip
24. 24. Connect upper radiator hose to thermostat housing • Remove 2x blanking plug • Secure clip
25. 25. Install ECT sensor (1) to thermostat housing assembly • Apply suitable sealant to threads • Secure sensor 22 Nm
26. 26. Connect harness connector (2) to ECT sensor • Secure lock

27. 27. Install heater outlet pipe with turbo pipe assembly to EGR cooler (1) • Install 3x bolt, secure 5x clip

28. 28. Install air cleaner assembly to battery tray and upper front panel • Push down to secure 2x locator to battery tray • Install 2x bolt (4)
29. 29. Secure harness for mass air flow meter to air cleaner assembly • Secure clip
30. 30. Secure outlet hose (1) to coolant expansion tank to air cleaner assembly • Secure clip
31. 31. Install air cleaner element to air cleaner assembly

Note. Before installing the air cleaner element, remove all debris from the air cleaner assembly.

32. 32. Secure cover (2) to air cleaner assembly • Secure 4x screw
33. 33. Connect harness connector (3) to (MAF) meter

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

34. 34. Fill coolant expansion tank with new coolant fluid up to maximum level mark
35. 35. Install cap to coolant expansion tank
36. 36. Connect battery negative lead • Secure nut 11 Nm
37. 37. Program all volatile memories – see operation “Program Volatile Memories”
38. 38. Start engine and allow it to run at idle speed until thermostat opens • Switch off engine

Note. Cooling system bleeds itself automatically during the warm-up phase.

39. 39. Check and correct coolant fluid level