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. Refer to Draining
- Remove intake manifold. Refer to Intake manifold, removing and installing .
- 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 Wastegate bypass regulator valve -3- (-N75-).
- Disconnect hose -4- from Wastegate 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. Refer to Filling .
- 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.
- 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:
Refer to
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
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
| Component | Nm |
| Coolant line bracket to cylinder block | 10 |
| Coolant line bracket to oil filter bracket | 20 |
| Coolant line bracket to coolant line flange | 10 |