Coolant Line/Hose: Service and Repair

Coolant line, removing and installing

Removing

Note: Always replace seals and gaskets.

- Obtain radio code on vehicles with coded radio.
- With the ignition switched off, disconnect the battery Ground strap.
- Drain coolant system. Service and Repair
- Remove intake manifold. Service and Repair




- Disconnect air duct -4- from air mass meter.
- Disconnect electrical connectors for air mass meter -1-.
- Unscrew bolts -2- and -3- and take off air cleaner housing.

Detach air intake hose from connection on turbocharger as follows:




- Disconnect vacuum hose -1- from air recirculation valve.
- Disconnect hose from pressure control valve for crankcase breather -2-.
- Disconnect electrical connector from charge pressure control valve -3- -N75-.
- Disconnect hose -4- from charge pressure control valve -N75-.
- Disconnect hose -5- at bulkhead (hose leads from solenoid valve to turbocharger).
- Take solenoid charge pressure control valve out of air intake hose and place it to one side on the engine.
- Pull retainer off turbocharger connection and detach air intake hose.
- Disconnect coolant hose from coolant pipe (hose leads to heat exchanger for heater).

Vehicle with automatic transmission



- Disconnect connectors:
1 - for solenoid valves (10-pin connector)
2 - for road speed sender -G68-

All vehicles:
- Unbolt coolant pipe retainer from coolant pipe flange on left of cylinder head.
- Disconnect hose (leading to oil cooler) from coolant pipe.
- Remove crankcase breather pipe.
- Unbolt coolant pipe retainer from cylinder block.
- Disconnect hose (leading to coolant expansion tank) from coolant pipe (right).
- Unbolt coolant pipe retainer from tensioning element for ribbed belt.
- Pull tapered collar off oil dipstick tube.
- Disconnect wires/unplug connectors as follows:
- Knock sensor I -G61-
- Engine speed sender- G28 (middle, gray)
- Knock sensor II -G66-
- Take connectors out of retainer.
- Unscrew oil pipe leading to turbocharger and unbolt retainer for oil pipe (both are attached to the oil filter bracket).
- Unbolt retainer for connectors.
- Unbolt knock sensors I and 11.
- Unbolt left - hand coolant pipe flange from cylinder head.
- Detach coolant pipe.


Installing
Installation is carried out in the reverse order:
- Before installing, clean and smooth down sealing surface for O-ring as required.




- Moisten new O-ring -1- with G 012 AS D and slide onto coolant pipe -2-.
- Push coolant pipe into opening in cylinder block.
- Fill up with coolant. Service and Repair
- After connecting battery terminals, enter anti - theft code for radio
Refer to Radio operating instructions
- Close electric windows in front doors all the way to their top positions using electric switches.
- Operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
- Set clock to correct time.
- Check DTC memory.

Note: DTCs will be stored in the memory because connectors have been unplugged. Therefore, check and erase DTC memory after installing the engine.


Tightening torques