Do-it-yourself thermostat repair Opel Vectra

In detail: do-it-yourself Opel Vectra thermostat repair from a real master for the site my.housecope.com.

Attention: Do not open the expansion tank cap and do not remove the thermostat until the engine has completely cooled down!

general information

1. The thermostat is designed to accelerate the engine warm-up process and divides the cooling system into two circuits: large and small. Until the coolant temperature reaches a certain value (as a rule, thermostats are adjusted to a temperature 80 - 90 "C) the thermostat valve is closed and the liquid circulates in a small circuit without entering the radiator. As a result, the engine quickly warms up to normal operating temperature. When a certain threshold value of the coolant temperature is exceeded, the thermostat filler begins to expand and opens the valve - the liquid begins to circulate in a large circuit through the radiator.

2. The thermostat housing is attached to the engine. The location of the thermostat can vary depending on the powertrain layout, but it is easy to find - it is always connected to the upper radiator hose.

3. Below is a detailed description of the procedure for removing / installing the thermostat on engines Z16XE / Z18XE for other engines, we will give only the differences and features.

Removal / Installation

4. Drain the coolant.

Comment: It is not necessary to drain the coolant completely. It is enough for the coolant level to drop below the thermostat housing.

5. Remove the engine cover (see Chapter 2) and, by loosening the clamp, disconnect the upper hose of the cooling system from the thermostat housing.

6. Disconnect the hose (see picture) cooling system, disconnect the coolant temperature sensor wiring connector, remove the 2 mounting bolts (on the Z16XE engine - 3 bolts) and remove the thermostat housing from the engine.

Video (click to play).

9.6 Thermostat housing (4) (on the example of the Z18XE engine) - the arrows indicate the fastening bolts

2 coolant hose

3 Connector wiring coolant temperature sensor

7. Check the thermostat (see below, if necessary, the thermostat together with the housing. When replacing, do not forget to reinstall the coolant temperature sensor in the housing of the new thermostat, tighten it to the required torque (see Specifications).

8. Install in the reverse order of removal. Replace the gasket before installation (see picture) thermostat and tighten the screws securing the thermostat housing to the required torque.

9.8 Replace thermostat gasket before installation

9. Fill the system with coolant.

10. Start the engine, warm up to operating temperature and check for leaks.

Features of the Z19DT engine

11. Remove the cooler (see picture) exhaust gas recirculation systems.

9.11 Elements of the cooling system of engines Z19DT (H)

2 Branch pipe of the cooling system

5 Exhaust Gas Recirculation Cooler

12. Disconnect the 3 coolant hoses from the thermostat housing.

Features of the Z19DTH engine

14. Remove the battery.

15. Separate the preheater control unit and carefully move it aside.

16. Bolt off the cooling system pipe and disconnect 4 hoses from the thermostat housing.

Features of Y20DTH / Y22DTR engines

17. Remove the turbocharger hose (

7.27).

18. Disconnect the preheating hose from the turbocharger to the regeneration valve and move it aside.

19. Remove the 4 fixing bolts and remove the housing (see picture) thermostat, and, if necessary, the coolant temperature sensor.

9.19 Thermostat housing (1) and coolant temperature sensor (2) (Y20DTH / Y22DTR engines)

Features of the Z20NET engine

20. When draining the coolant, unscrew the drain plug located at the bottom of the water pump. (see figure).–

9.20 Drain plug (arrow) of the water pump (Z20NET engine)

21. Remove the air cleaner and remove the vacuum pump.

22. Remove the 3 bolts (see picture) fasteners and remove the thermostat housing.

9.22 Bolts of fastening of the housing (1) of the thermostat (Z20NET engine) the arrow indicates the position of the third bolt

23. Installation is carried out in the reverse order of removal. Remember to replace the vacuum pump gasket, wrap the threads with Teflon tape or sealant before screwing in the water pump drain plug.

Features of Z22SE / Z22YH engines

24. When draining the coolant, unscrew the drain plug (

9.20).

25. Loosen the clamp (see picture) fasteners and disconnect the hose from the thermostat housing. Remove the 2 mounting bolts and remove the thermostat housing from the motor.

9.25 Bolts (2) of the thermostat housing and the fastening clamp (1) of the coolant hose (engines Z22SE / Z22YH)

26. Installation is carried out in the reverse order of removal. Remember to replace the thermostat gasket by lightly greasing it with silicone grease (white). Before screwing in the water pump drain plug, wrap the threads with Teflon tape or sealant.

27. The main reason for the failure of the thermostat is the aging of the filler and its loss of the ability to significantly change its volume depending on the temperature. During operation, mechanical damage to the thermostat valve may occur.

28. Preliminary operation of the thermostat can be checked without removing it from the engine. With the engine running, open the hood and touch the upper radiator hose.

Attention: Be careful - you can burn your hand if the coolant temperature is high!

If the engine is just started and did not have time to reach operating temperature, and the liquid in the upper hose is already warm, then the thermostat valve is not closed. This is also indicated by a slower than usual increase in the temperature of the coolant, and in winter - a decrease in the power of the heater. If the warning lamp (Controls and operating methods ") of the coolant temperature on the instrument panel has been activated, and the upper branch pipe is cold, it can be guaranteed that the valve does not open a large circuit.

Comment: This is only an approximate way of checking, while you need to be sure that all other components of the cooling system and temperature control are functioning properly, the coolant level is normal.

Follow the recommendations in the section on diagnosing problems with the cooling system.

29. The most accurate results are obtained by checking the thermostat on a workbench.

30. Remove the thermostat from the engine (see above).

31. Tie a piece of wire to the thermostat assembly and lower it into a container filled with water (see figure). Lower the thermometer there.

9.31 Checking the correct functioning of the thermostat

Attention: Make sure that the thermometer and thermostat do not come into contact with the walls and bottom of the container

32. Begin to slowly warm up the water, watching the change in the thermometer readings. The thermostat valve actuation must be in exact accordance with the control settings for the specific engine model (see Specifications).

9.33 Checking the completeness of opening of the thermostat valve

33. Estimate the value of full opening of the valve, - the nominal value is b – a = 8 mm (see figure). If any deviations are found, replace the thermostat.

Opel Vectra S coolant expansion tank cap.

Connect the hose to the socket and turn on the tap.

Drain coolant into a container in such a quantity that the level in the cooling system is below the thermostat housing.

Turn on the tap and remove the hose.

Thermostat housing retaining bolts.

Unscrew the bolts with the head 10.

Remove the upper part of the housing.

Pry off the thermostat with a screwdriver.

Install in the lower part of the housing.

Install the upper part of the housing.

Add antifreeze to the expansion tank.

Replacing the thermostat on the Opel Vectra C may be necessary if there are problems with engine cooling. The engine overheats, or vice versa - the antifreeze does not reach operating temperature, the circulation of the coolant is impaired - all this may indicate a faulty thermostat. It is not so difficult to change it with your own hands.

First you need to unscrew the coolant expansion tank cap and drain the liquid. It is recommended to do this with the engine cold to avoid burns. It is not necessary to drain all the liquid, it is enough for the level of antifreeze to fall below the thermostat. You can reduce the coolant level by connecting the hose to the drain at the bottom of the radiator and unscrew the tap. Then drain the antifreeze into the prepared container.

Next, you need to remove the plastic cover of the thermostat motor and unscrew a pair (three on the Z16XE engine) housing bolts head 10... By removing the housing, the thermostat can be removed. The installation of a new thermostat is carried out in the reverse order. At the end, you need to compensate for the loss of coolant by adding it to the expansion tank. Topping up should be done only with red (dark orange) antifreeze Opel 1940650 or analogs.

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Photo of the WAHLER 4431.105 thermostat assembly on the Opel Astra car.

The reasons for replacing the thermostat on the Opel Astra are easily diagnosed:

temperature instability of the engine - constantly overheats or heats up for a long time;
the appearance of the corresponding icon on the instrument panel (car with a wrench).

After a message appears on the dashboard about the malfunction that has occurred, the error must be read.

If the problem is with the thermostat, the following will be displayed: Thermostat Heater Control Circuit / Open.

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On the 1.7-liter SOHC diesel engine, the thermostat is located on the left side of the cylinder head, on the DOHC engine on the right.

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Remove the negative and then positive terminals from the battery.

Drain off coolant.

Unscrew the battery holder.

Get out the battery.

Unscrew the 3 bolts securing the platform for the storage battery and disconnect the wires.

Remove the site.

Move aside the blue strip from the clamping pedal. Opel combo 1 3 diesel repair do it yourself. To remove the terminal from the thermostat housing, you must remove the blue strip from the terminal lock pedal. Do-it-yourself video lesson on replacing the thermostat on an Opel Astra G car. news Repair opel cadet do it yourself video The procedure is performed only with a clock screwdriver. Popular Repair steering rack Nissan Sunny do it yourself video A standard screwdriver will break the limiter.

Step on the pedal and remove the terminal.

Squeeze the ears of the clamp off the thermostat pipe using a pair of pliers.

Remove the thermostat by sliding it along the hose.

Remove the 4 bolts securing the hose to the thermostat housing.

Dismantle the thermostat housing.

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for a very long time looking for the problem of overheating of one corsa
in place until the car is moving at least gas the temperature is normal, the fan turns on as expected, the temperature drops
in motion, especially under load, scales up to the release of antifreeze through the plug
sometimes you could hear the seething in the cabin
watched the piston through the spark plug hole
there is no wash, the car does not troit either in the morning or further
helped by grinding the head and replacing the gasket
antifreeze did not enter the combustion chamber, but gases burst into the cooling systemthe cooling system for gas breakthrough can be checked with a conventional gas analyzer
for CO in the system by inserting the gas analyzer probe directly into the expansion tankthe radiators are new, when the stove heater is turned on at idle, the temperature drops, but if at a constant speed, it remains unchanged at whatever speed of the stove fan I set.I wrote in the next topic, but I will repeat if this is normal:Well tell the astrovody. is all of the above normal. (I will remind you that I changed the thermostat to Vahler 4431.105D).The thermostat activates the large cooling circuit when the engine warms up.At the same time, the thermostat continuously expands, from size "a" to size "b".1. Remove the thermostat housing.2. Check the position of the thermostat through the connection in the housing. Measure dimension "a" on the thermostat.3. If the thermostat is open at room temperature, it is faulty and must be replaced.
4. For a rough check of the thermostat's performance, hang its body on a piece of twine in a vessel with water. The thermostat housing must not touch the vessel walls. Start heating the vessel.
5. As the water heats up, the thermostat should open (this happens just before the water boils).Since the boiling point of water is 100 ° C, the thermostat may not open fully (refer to Specifications). Remove the thermostat and let it cool down. As it cools, it should close completely.
6. If the thermostat does not open when heated or does not close when cooled, replace it.
7. When installing the thermostat, keep the following in mind:a) Thoroughly clean the mating surfaces and replace the O-ring.
b) Place the thermostat in the housing in the correct orientation.
c) Tighten the cover bolts with the required torque.
d) Install all hoses to their original places, then fill in coolant (refer to Chapter Ongoing maintenance).
e) Start the engine, warm up to operating temperature and check for leaks.Are you here »Vectra Club Murmansk» Renovation of Vectra A »Installation of thermostat on C16NZ

Edited by Niko (2011-11-21 12:24:13)

Niko
what Daedalus. )
- she is from Moscow!)

– Anna
Yes, this cannot be just simply)

what hairpins ?? .. what nonsense - two bolts and that's it.
Of course, if mishandled, they can be broken. which apparently they were afraid of on the server)) - with an absurd excuse

that there may be some hairpins that are difficult to buy.

- but in any case - and it can be overcome

I can only recommend one thing - to find a Good Specialist!
are there really no such people in Moscow?

well, or come to us)
- we will help then)

Just tell me how to contact you
But you are from Murmansk. far away.
I'm afraid my old lady will not reach you.
Edited by Anna (2011-11-21 13:06:53)
- - Ouch.
    boys but I didn’t see that this is a forum of Murmansk.
    - - And the stove does not heat.
        By the way. for one. Soon it will be quite cold here and my gearbox will make itself felt. in severe frosts, the rear front does not turn on if the car is not warmed up for 20 minutes. Does this mean that you need to change the oil in the box or what other reasons are there for that?
        Well, I think I found guys who will put me a thermostat.
        I have the following question. When changing thermostat, do you need to change antifreeze?
        Otherwise, you don't want to run around in the store 10 times.
        
        what hairpins ?? .. what nonsense - two bolts and that's it.
        Of course, if mishandled, they can be broken. which apparently they were afraid of on the server)) - with an absurd excuse
        
        If suddenly the bolts break - is it not difficult to find them for replacement? What are these bolts?
        If possible, a picture.
        that would be safe for earlier.
        And so my friends will start and I’m going my story today, I’m going to another city and I notice that my temperature does not rise above 80 degrees. then 80 then drops to 40 and stalemate and completely to zero when I'm already tired of looking at these problems let me think I'll stop and see what's the matter I'll smoke while I smoked and looked under the hood the temperature rose from zero to 90 degrees but I think I have a sensor glitch or else something and drove on. But it was not there, before I had time to get under way, the temperature began to drop when driving, and so sharply. Calling a friend, he said most likely a thermostat. Well, I think I probably got hryvnia so the mood fell by 500. When I drove into the store to find out its price, my mood was not that it fell just oh. I ate from what I heard 1600 hryvnia, this is not counting the antifreeze and work, well, I think there is nothing I got on 2000 kilograms of hryvnia and this is for some kind of thermostat.
        
        Friends, help with advice which thermostat to buy can where it is cheaper to eat?
        
        And another question who bought the thermostat from the Chevrolet Cruze, they say that it is better.
        
        Respond to all not indifferent Comrades Clubmates.
        
        I also read such information that a person soldered holes in the thermostat with a soldering iron and goes on whoever has practiced this?
        
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        The device of a car is a rather complicated thing, but this is only at first glance.With a minimal understanding of its structure and principle of operation, you can easily perform some simple types of repair work with your own hands, that is, independently. This will allow you to significantly save on the services of service centers.
        
        If the engine overheats, you cannot avoid problems, therefore, in order to prevent this, you should be attentive to the "temperature rise" of the car. You just need to make it a rule to perform a fairly simple ritual of checking the thermostat for normal operation, and if necessary, replace it in a timely manner.
        
        Let's start simple. What is a thermostat? This is a small device that performs its main function of maintaining a constant temperature in the internal combustion engine. The thermostat during engine operation is able to block antifreeze, preventing it from entering the radiator until it is fully warmed up. As long as it is closed, the coolant will move in a small circle in order to ensure a gradual warming up of the engine. After the temperature of the internal combustion engine reaches 95 degrees, the thermostat opens and the already heated liquid begins to circulate in a large circle and enters the radiator.
        
        The thermostat has rather difficult working conditions. It is constantly exposed to corrosive liquids and, as a result, the formation of corrosion. It is possible to determine the malfunction or complete failure of the thermostat in this way. Start the engine and wait until it has warmed up sufficiently to its optimum operating temperature. Then turn off the ignition and open the hood, touch the radiator hoses: first to the top and then to the bottom. Ideally, both of these hoses should be hot enough. If one hose is cold, you can safely conclude that the thermostat is broken. By the way, look at the same time, before you close the hood, if your radiator needs cleaning, as this can also cause overheating.
        
        In order to replace the thermostat with your own hands, you will need the following kit:
        
        3. Plastic containers: one 5 liter and one 1 liter.
        
        5. And of course a new thermostat, of course.
        
        If you have everything you need and you are ready to start the "fun".
        
        To replace the thermostat, you need to disconnect the air intake pipe in two places: from the right pillar near the headlight, and also from the air filter housing. After that, let the engine cool down a little, then slowly, carefully and carefully reduce the pressure in the cooling system. This is done gradually by unscrewing the expansion tank plug.
        
        Next, you will need the plastic containers prepared earlier. The five-liter must be cut into two parts so that such a "tongue" is formed in the lower part of the container. It is this part of the bottle that will come in handy for you, substitute it from below in such a way that this tongue clings tightly to the thermostat module.
        
        After completing this simple operation, you can begin to loosen the thermostat mounting bolts. It is important to remember the strict sequence of this procedure, start from the bottom to the top, then to the one located at the back. The lower bolt, the one that is lower than the others, using a 10 key, unscrew two or three turns. The bolt that is on top must be unscrewed one or two turns, but the rear bolt - strictly one. Such manipulations, in the end, will lead to the formation of a gap in the front part, through which the coolant will flow into the plastic container according to a special tongue made by you. If necessary, you can help slightly by slightly opening the gap.
        
        After about 1 liter of coolant has drained, you can unscrew the bolts a little more, while very carefully insert a flat screwdriver into the slot and slide the thermostat. This should be done with extreme caution as there is a high likelihood of damage to the thermostat gasket.
        
        Video (click to play).
        
        Once there are about 3 liters of antifreeze in the plastic bottle, you can filter it out with a bandage or gauze, then pour it over a whole plastic bottle. Put the cut-off bottle under the thermostat again, and unscrew the bolts to the end and dismantle the faulty thermostat. Install the new unit carefully in the same place, making sure that the spring is turned towards the engine. Next, tighten the bolts and unscrew the plug that releases air, it is located on the hose that leads to the stove. After that, pour the filtered antifreeze back into the system and tighten all the plugs. Check all the bolts carefully and only then try to start the engine.
        
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