Front Coolant Pipe

Front Coolant Pipe

Special tools, testers and auxiliary items required

• Hose Clip Pliers (VAS 6362)

Removing

- Remove the oil filter bracket. Refer to => [ Oil Filter Bracket with Oil Cooler ] Oil Filter Bracket With Oil Cooler.

- Remove the battery.





- Remove the bolts - arrows - and remove the battery tray - 1 -.





- Disconnect the connector - 3 - from the intake flap motor (V157) or from the throttle valve control module (J338).





- Remove the coolant hose by loosening the hose clamp - 4 -.

- Remove the bolt - 2 - on the EGR pipe.

• Ignore - 1 - and - arrow -.

- Remove the bolts - arrows - and then remove the intake flap motor or the throttle valve control module.





- Press the release buttons and remove the crankshaft housing ventilation hose - 1 - from the cylinder head cover.





- Free up the vacuum hoses - arrows - on the air guide pipe.

- Loosen the hose clamp - 2 - and remove the air guide pipe.

- Remove the wiring harness from the bracket - arrow -.





- Loosen the hose clamps - arrows - and remove the coolant hoses from the transmission fluid cooler.





- Free up the wiring harness - arrows - and the connector - 1 - on the bracket.





- Remove the bolts - 2 and 5 - and - arrows -.





- Free up the electrical wires and the hoses on the left air guide pipe using the pry lever - rmv outside mirror (80 - 200).

- Loosen the hose clamp - 3 - and remove the left air guide pipe.

• Ignore - 1 and 4 -.


Danger of cracking the coupling.

• Do not bend coupling inside the EGR pipe.

- Remove the nuts - 1 - and bolts - 2 - and remove the EGR pipe.





- Remove the nut - 2 - on the vacuum line clamp.





- Remove bolt - 1 -.

- Loosen the union nut by counterholding it with an open-end wrench - 3 - and remove the oil supply line from the turbocharger connection.

- Disconnect the - 2 - camshaft position sensor (G40) connector.





- Remove the bracket from the front coolant pipe.

- Open the clamps - 1 - and - 3 - and remove the coolant hoses.

- Remove the bolts - arrows - and move the front coolant pipe to the left.

Installing

• Tightening specifications, refer to => [ Coolant Pipes, Coolant Temperature Sensors and Coolant Pump Assembly Overview ] Coolant Pipes, Coolant Temperature Sensors and Coolant Pump Assembly Overview.

• Tightening specifications, refer to => [ Oil Filter Bracket and Oil Cooler Assembly Overview ] Service and Repair.

Installation is in reverse order of removal, note the following:

• Replace seals, gaskets and O-rings.

• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.

• In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

- Clean and/or smooth the sealing surfaces of the O-rings.

- Coat the O-ring with coolant and slide it onto the front coolant pipe.

- Install the front coolant pipe into the coolant pipe.

- Install the oil supply line. Refer to - 6 - => [ Oil Supply Line ] Service and Repair.

- Install the exhaust gas recirculation pipe => [ Exhaust Temperature Control Assembly Overview ] Exhaust Temperature Control Assembly Overview.

- Install the left air guide pipe. Refer to => [ Charge Air Cooler Assembly Overview ] Charge Air Cooler Assembly Overview.

- Install the intake flap motor or the throttle valve control module.

- Install the battery tray and the battery.

- Install the oil filter bracket. Refer to => [ Oil Filter Bracket with Oil Cooler ] Oil Filter Bracket With Oil Cooler.

- Fill with coolant. Refer to => [ Filling ] Procedures.