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Thermostat Bypass Pipe Replacement

1. Remove the engine water outlet adaptor. Refer to Engine Water Outlet Adaptor Replacement : 2.0L Diesel LNP .
2. Remove the thermostat bypass hose. Refer to Thermostat Bypass Hose Replacement .



3. Remove the surge tank outlet front hose clip (1) and the surge tank outlet front hose (2) from the surge tank outlet pipe (5).
4. Remove the heater outlet hose clip (3) and the heater outlet hose (4) from the surge tank outlet pipe (5).



5. Remove the surge tank outlet rear hose clip (5).
6. Remove the surge tank outlet pipe bracket bolt (3) from the inlet manifold (2).
7. Remove the surge tank outlet rear hose along with the surge tank outlet pipe (4) from the thermostat bypass pipe (1).
8. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .



9. Remove the engine oil cooler outlet hose clip (2) and the engine oil cooler outlet hose (3) from the thermostat bypass pipe (1).
10. Remove the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement : 2.0L Diesel LNP .



11. Remove the 2 thermostat bypass pipe bolts (1) from the thermostat bypass pipe bracket (2).



12. Remove the water pump inlet hose clip and the thermostat bypass hose clip (1) from the thermostat bypass pipes.
13. Loosen the engine coolant inlet hose clip from the thermostat bypass pipe and move the thermostat bypass pipes along with the thermostat bypass pipe bracket (2) aside (see arrow).



14. Remove the exhaust gas recirculation manifold cooling return hose clip (3) and the exhaust gas recirculation manifold cooling return hose (2) from the thermostat bypass pipe (1).
15. Remove the thermostat bypass pipe bracket bolt (4) and remove the thermostat bypass pipe (1) in direction of arrow.

Caution: Refer to Fastener Caution in the Preface section.




1. Position the thermostat bypass pipe (1) on the engine and install the thermostat bypass pipe bracket bolt (4). Tighten the bolt to 10 N·m (89 lb in).
2. Install the exhaust gas recirculation manifold cooling return hose clip (3) with the exhaust gas recirculation manifold cooling return hose (2) to the thermostat bypass pipe (1).



3. Position the thermostat bypass pipes along with the thermostat bypass pipe bracket (2) to the thermostat bypass hose and the engine coolant inlet hose (4).
4. Install the engine coolant inlet hose clip (3) to the thermostat bypass pipe (2).
5. Install the thermostat bypass hose clip and the water pump inlet hose clip (1).



6. Install the 2 thermostat bypass pipe bolts (1) to the thermostat bypass pipe bracket (2) and tighten to 22 N·m (16 lb ft).
7. Install the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement : 2.0L Diesel LNP .



8. Install the engine oil cooler outlet hose clip (2) with the engine oil cooler outlet hose (3) to the thermostat bypass pipe (1).
9. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .



10. Install the surge tank outlet rear hose along with the surge tank outlet pipe (4) to the thermostat bypass pipe (1) and install the surge tank outlet rear hose clip (5).
11. Install the surge tank outlet pipe bracket bolt (3) to the inlet manifold (2) and tighten to 9 N·m (80 lb in).



12. Install the heater outlet hose (4) to the surge tank outlet pipe (5) and install the heater outlet hose clip (3).
13. Install the surge tank outlet front hose clip (1) with the surge tank outlet front hose (2) to the surge tank outlet pipe (5).
14. Install the thermostat bypass hose. Refer to Thermostat Bypass Hose Replacement .
15. Install the engine water outlet adaptor. Refer to Engine Water Outlet Adaptor Replacement : 2.0L Diesel LNP .