Installing thermostat
Note. All seals between opened sealing surfaces must be replaced.
Scheme 79
1. Insert thermostat in the cover and turn it until the two sheetmetal edges are lying to the left and right of the holder.
2. Replace inner and outer seal in thermostat housing cover.
3. Position thermostat housing cover and tighten the fastening screws (M6 x 25) according to the sequence shown. --> Tightening torque: 7.5 ftlb.
Scheme 80
4. Tighten the three rear fastening screws (M6 x 16) on the heater pipes. --> Tightening torque: 7.5 ftlb.
5. Connect vent lines for cylinder heads. The connectors must engage audibly.
6. Fit coolant line leading to the generator. Insert the line in the thermostat housing cover and tighten the fastening screw. --> Tightening torque: 7.5 ftlb.
7. Push coolant line onto generator and fit the spring-band clamp.
8. Push the holder onto the timing case cover below the cable duct and tighten the fastening screw. --> Tightening torque: 7.5 ftlb.
Scheme 81
9. Tighten the upper fastening screw of the oil dipstick. --> Tightening torque: 7.5 ftlb.
Scheme 82
10. Push the cable duct onto the retaining bracket over the coolant pump.
11. Check whether the drive belt is correctly installed.
12. Fit coolant supply and return hose on thermostat housing cover.
1. Install intake distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .
2. Fill coolant system and check for leaks. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"
1. Remove transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP) or refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne MAN) .
2. Remove the front engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .
3. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)
Scheme 83
1- - O-ring; replacing. (Scheme 83)
2- - Clamp; replace if damaged. (Scheme 83)
3- - Thermostat housing. (Scheme 83)
4- - --> Tightening torque: 6 ftlb. fastening screw. (Scheme 83)
5- - Coolant regulator; pay attention to the direction of installation --> Start of opening temperature: 80 °C --> End of opening temperature: 107 °C --> Opening stroke: 7 mm. (Scheme 83)
6- - Adapter; pay attention to the installation position. (Scheme 83)
7- - Molded seal; replacing. (Scheme 83)
8- - Temperature sensor for coolant temperature. (Scheme 83)
9- - Plug. (Scheme 83)