Coolant Line/Hose: Service and Repair

Coolant line, removing and installing

Removing

Note:
Always replace seals and gaskets.

- Obtain radio anti-theft code on vehicles with coded radio.
- With the ignition switched off disconnect the battery Ground (GND) strap.
- Drain cooling system
- Remove intake manifold.





- Disconnect air duct -4- from Mass air flow sensor.
- Disconnect electrical connectors for Mass air flow sensor -1-.
- Remove 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 waste gate bypass regulator valve -3- (-N75-).
- Disconnect hose -4- from waste gate bypass regulator 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 line (hose leads to heat exchanger for heater).

Vehicles with automatic transmission





- Disconnect connectors:

1 - For solenoid valves (10-pin connector)

2 - For Vehicle Speed Sensor (VSS) -G68

All vehicles:

- Unbolt coolant pipe retainer from coolant line flange on left of cylinder head.
- Disconnect hose (leading to oil cooler) from coolant line.
- Remove crankcase breather line.
- Remove coolant line retainer from cylinder block.
- Disconnect hose (leading to coolant expansion tank) from coolant line (right).
- Remove coolant line retainer from tensioning element for ribbed belt.
- Pull tapered collar off oil dipstick tube.
- Disconnect wires/connectors as follows:
- Knock Sensor (KS) 1 -G61-
- Engine Speed (RPM) Sensor -G28- (middle, grey)
- Knock Sensor (KS) 2 -G66-
- Take connectors out of retainer.
- Remove oil line leading to turbocharger and unbolt retainer for oil line (both are attached to the oil filter bracket).
- Unbolt retainer for connectors.
- Unbolt Knock Sensor (KS) 1 and 2.
- Unbolt left-hand coolant line flange from cylinder head.
- Detach coolant line.

Installing

Installation is carried out in the reverse order, when doing this note the following:

- Before installing, clean and smooth down sealing surface for O-ring as required.





- Moisten new O-ring -1- with G 012 A8 D and slide onto coolant pipe -2-.
- Push coolant pipe into opening in cylinder block.
- Fill up with coolant.
- After connecting battery terminals, enter anti-theft code for radio
- Close electric windows in front doors all the way to their top positions using electric switches.
- Then 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.
- Interrogate DTC memory

Note:
DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.

Tightening torques