TD6 '02 FFRR Thermostat Exchange (sort by title) |
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16 - Disconnect Fan Cowl - Electrical Connections – 844 viewsUndo the two electrical connectors on the fan cowl (left hand side facing engine). For the top one you need to unclip the female as well (securing clip is below at the back, and unclip the cable further down)
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17 - The Vicious Coupling! – 895 viewsAt last we have sight of the viscous (vicious!) coupling nut. The nut is left hand threaded, so facing the car from the front you need to undo it clockwise. Others have been able to release the nut with one spanner and a tap with a hammer, but not me, not enough resistance on the water pump / belt.
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22 - Turbo Air Duct – 886 viewsRemoving the turbo air duct. First outer allen bolt is easily accessible, the other one is a right bugger to get at, better left until the fan cowl is removed. Make sure you have allsorts of skinny extensions to get at the second one, and a bit of rubber tube to make it easier to turn the bolt once you get it going
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18 - Removing the Viscous Coupling – 851 viewsMake sure you can remove the viscous coupling fan before you start removing other bits or drain the cooling system. Getting the 32mm spanner on the vc nut can be tricky as the nut can be rusted "bigger". Spray some WD 40 to ease things.
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19 - Removing the viscous coupling – 860 viewsI needed a skinny vc spanner from Halfords to hold the pulley nut in place so I could loosen the vd nut and another 32mmm spanner to loosen the vc nut. The skinny spanner rested on the pulley below and then the vc nut cracked off with a simple tap of the hammer on the big spanner. You can then remove spanners and spin the fan.
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20 - Lift out the fan and cowl – 846 viewsLift out the viscous coupling fan. Then carefully remove the fan cowl. Pull the radiator top hose back to give enough room for the side clips to pass. These are fragile so don't snap them off like what I did.
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21 - Turbo Air Duct – 854 viewsTurbo air duct removed - it just pulls off at the bottom.
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43 - Tighten up radiator drain and remove drain hose – 824 views
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23 - Draining off the coolant – 831 viewsThe radiator tap. (look down below the fuel cooler air intake) I warmed up some plastic hose I had in a cup of boiling water, shoved a sealant nozzle into one end to widen it, then pushed it over the drain fitting and allowed to cool before opening the tap. The tap was pretty tight so needed some big pliers to get it moving. Don't undo too far, just enough to get the coolant running out of the hose. It can take a good 15 minutes to drain.
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20 - Fan Cowl Side Clips – 789 viewsOn removing the fan cowl I broke off one of the tabs (on the left) so be careful when removing this part. Superglued and duct taped back into place. I hope it holds.
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24 - What you can see with fan cowl removed – 910 views
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25 - Removing EGR Cooler – 952 viewsCan nearly see the thermostat now, just need to remove all the EGR pipework
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