!Guide! Replacing Thermostat/Thermostat Housing - MK7 2011

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-Ford Fiesta Zetec JA8 1.25 duratec 16v petrol 08-13

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Misc:
-The stretch belt needs to come off & is really awkward to install without a guide tool (Buy one)

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-Make sure that the engine is cold
-Unfasten the bottom radiator hose (catch the coolant in a bucket) 
-Refit the bottom radiator hose (Make sure the notches line up on the hose & spring clip)

-Unfasten the 10mm bolt on the negative battery terminal
-Securely position the negative terminal to one side

-Crack off the wheel nuts for the front right wheel (19mm)
-Support the front right corner of the car with axle stands
-Remove the front right wheel (19mm) 

-Remove the 2 T27 torx screws that are securing the plastic splash guard that's covering the crankshaft pulley
-Remove the splash guard

-Remove the 15mm pivot bolt for the alternator (positioned underneath towards the top of the engine)
-Remove the 15mm bolt from the front of the alternator
-Remove the 15mm nut from the front of the alternator
-Remove the E8 inverted torx stud from the front of the alternator

-Manoeuvre the alternator so that you can free the drive belt from the alternator pulley 

-Pull the rubber boot covering the positive terminal on the alternator
-Remove the 13mm nut on the positive terminal on the alternator 
-Unplug the wiring connector for the alternator

-Remove the alternator

-Unclip & remove the 2 rubber pipes going into the thermostat housing
-Remove the 4 8mm bolts that are securing the thermostat housing to the engine (Catch the coolant in a bucket underneath) 
-Pull the thermostat housing & thermostat away from the engine (Make a note of the orientation of the thermostat)

-Use degreaser & abrasive material to fully clean & rinse any dried coolant from the surrounding area on the engine. Especially where the thermostat seals to the engine. 
-Remove the O ring from the thermostat housing & use degreaser & a nylon brush to clean the housing (If you are not replacing it)

-Fit the new thermostat (Orient it the same way that it came off)
-Fit the new thermostat housing (Replace the O ring if you are using the old thermostat housing)
-Hand screw the 4 8mm bolts (Ideally replace them)
-Torque the 4 8mm bolts @ 11Nm
-Refit the 2 hoses & hose clamps (Make sure that the notches line up with the hoses & spring clamps)

-Place the alternator back in position
-Clip the wiring connector into the alternator (Make sure it clicks)
-Secure the positive wire to the alternator with the 13mm nut @ 20Nm
-Install the rubber boot on the positive terminal

-Hand screw the alternator stud (Ideally replace it)
-Hand screw the 2 15mm alternator bolts (Ideally replace them)
-Torque the E8 inverted torx stud & 15mm nut to @ 48Nm (Ideally replace the nut)
-Torque the 2 15mm alternator bolts to @ 48Nm

-Feed the drive belt down over the alternator pulley, AC pulley, and around the water pump pulley (Consider replacing the drive belt)
-Feed the belt half over the crankshaft pulley
-Fit the stretch belt guide tool to the crankshaft
 
-Turn the crankshaft clockwise with a 18mm socket to guide the belt on
-Turn the crank pulley 5 more times to fully seat the belt
 
-Check that all of the ribs on the crankshaft, AC compressor, and alternator line up with the ribs on the belt
 
-Reinstall the crankshaft splash guard with the 2 T27 torx screws
 
-Apply a conservative amount of aluminium anti seize to the hat of the rotor (Don't get any on the studs)
-Reinstall the wheel (19mm)
-Lower the car back down
-Torque the wheel nuts to 110Nm

-Add 50/50 concentrated antifreeze and deionised water until at the max fill line

-Tighten the 10mm negative battery terminal @ 25Nm

-Follow the bleeding procedure for the engine coolant

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Useful sources:

How To Replace Thermostat FORD FIESTA 1.6L 2012~2013 HXJA 6DCT250 6 DSG

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