Upper Right Coolant Pipe, Removing And Installing

Special tools and workshop equipment required 

• Hose Clamps - Up To 25mm3094

Removal

Fig 1: Identifying Engine Cover -Arrows-

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-- Carefully pull the engine cover off the 4 bolts one after the other -arrows-.

-- Remove the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

Fig 2: Identifying Bolts -Arrows-

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Vehicles through 05/2010:

Fig 3: Identifying Connector -3- And Bolts -4-

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-- Disconnect the connector -3- on the Intake Flap Motor -V157-.

-- Remove the screws -4- and move the Intake Flap Motor -V157-, with the connecting rod -1- still attached, to the side.

-- Remove the bolt -1- and banjo bolt -3- for the oil supply line on the turbocharger.

Fig 4: Identifying Bolt -1- And Banjo Bolt -3- And Move Turbocharger Oil Supply Line To Side

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-- Move the oil supply line to the side.

All Vehicles:

Fig 5: Identifying Electrical Connector -1- And Hose Clamps -Arrows-

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-- Disconnect the glow plug connectors for cylinders "1" and "2".

-- Free up the wiring harness on the right upper coolant pipe.

-- Disconnect and remove the coolant hoses and Hose Clamps - Up To 25mm3094, to do this, loosen the hose clamps -arrows-.

-- Remove the right upper coolant pipe.

Installation

Install in reverse order of removal. Note the following:

• Tightening specification. Refer to COOLANT PIPES OVERVIEW .

-- Install the oil supply line. Refer to TURBOCHARGER OVERVIEW .

-- Install the Intake Flap Motor -V157- and the intake manifold upper section. Refer to OVERVIEW - INTAKE MANIFOLD .

-- Check the coolant level, refer to COOLANT, DRAINING AND FILLING .