Rear Coolant Pipe

Rear Coolant Pipe

Special tools, testers and auxiliary items required

• Refractometer (T10007 A)

• Hose Clamps up to 25 mm Dia. (3094)

• Cooling System Tester (V.A.G 1274 B)

• Adapter (V.A.G 1274/8)

• Hose Clip Pliers (VAS 6340)

• Drip Tray for VAS 6100 (VAS 6208)

• Pry Lever - Rmv Outside Mirror (80 - 200)

• Hose Clip Pliers (VAS 6362)

• Transportation Lock (T10404)

• Wrench SW 13 (T10384)

Removing

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

• Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.

• Hose clip pliers (VAS 6340) are recommended for installing spring-type clamps.

• When installing coolant hoses, make sure they are free of stress and do not come into contact with other components (observe markings on coolant connections and hoses).

- Remove the noise insulation.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the NOx reduction catalytic converter. Refer to => [ NOx Reduction Catalytic Converter ] NOx Reduction Catalytic Converter.

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the heated oxygen sensor and the oxygen sensor heater. Refer to => [ Heated Oxygen Sensor G39 with Oxygen Sensor Heater Z19 ] Heated Oxygen Sensor G39 with Oxygen Sensor Heater Z19.

- Remove the exhaust pressure sensor 1. Refer to => [ Exhaust Pressure Sensor 1 G450 ] Service and Repair.

- Remove the exhaust gas temperature sensor 2. Refer to => [ Exhaust Gas Temperature Sensor 2 G448 ] Exhaust Gas Temperature Sensor 2 G448.

- Remove the exhaust gas temperature sensor 3. Refer to => [ Exhaust Gas Temperature Sensor 3 G495 ] Exhaust Gas Temperature Sensor 3 G495.

- Remove the exhaust gas temperature sensor 4. Refer to => [ Exhaust Gas Temperature Sensor 4 G648 ] Exhaust Gas Temperature Sensor 4 G648.

- Release the clips - arrows - and remove the upper toothed belt guard.






- Unclip the wires from the cover.

- Remove the particulate filter mount bolts - 1 -.






- Loosen the clamp - 1 - for the connection between the turbocharger and the particulate filter and remove it.






• The illustration shows the clamp - 1 - bolt from underneath. This can also be installed from above in some cases.

- Release and disconnect the connector - 2 - from the differential pressure sensor.






- Free up the fuel lines on the mount.

- Remove the bolt - 1 - and set the mount aside.

• Lower the differential pressure sensor together with the wires and the particulate filter.

- Remove the nut - arrow - and then remove the bracket - 1 - from the upper cylinder head.






Danger of causing damage to the coupling element.

- Secure the coupling element using the transportation lock (T10404) - arrow -.






- Remove the drive axle heat shield bolts - 1 - and shield.






- Remove the right drive axle from the flange, lay it down and secure it.

- Loosen the clamp - 2 - and remove it.






- Remove the nuts - 1 - using the wrench SW 13 (T10384).






- Remove the nuts - 2 - and remove the mount.

- Push the particulate filter downward so that it lays on the subframe.






- Seal all openings with plugs from the engine bung set (VAS 6122).

• The particle filter must not be removed from the vehicle.

- Lower the particulate filter so that it is touching the steering gear.

• Pay attention to the exhaust gas temperature sensor and the heated oxygen sensor when lowering onto the cable in order to avoid any damage.

- Loosen the clamps and remove the coolant hoses - arrows - from the coolant pipe - 1 -.






- Remove the bolt - 2 - and remove the nut - 3 -.

- Remove the coolant pipe - 1 -.

Installing

Install in reverse order of removal. When doing this note the following:

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

• Secure the hose connections with standard production clamps. Refer to the Parts Catalog.

- Electrical connectors and wiring routing.

- Fill the coolant. Refer to => [ Draining and Filling ] Procedures.

Tightening Specifications