Replacing the coolant line from the cylinder head to the coolant expansion tank

WARNING: Working on 12 V electrical system.
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

WARNING: Hot fluids.
Risk of scalding!

Conduct all work in the vehicle wearing appropriate personal protective equipment only.

CAUTION: Materials harmful to health.
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

NOTE: TECHNICAL INFORMATION
Follow notes for repair work on the cooling system.
For additional information see: NOTES FOR WORKING ON THE COOLING SYSTEM .

NOTE: TECHNICAL INFORMATION
Filling without the vacuum filling equipment (watering can filling) is not permitted.
If this is not observed, there is a risk of component damage or engine damage.
The filling specification must be observed.
It is essential to visually check the vacuum filling equipment before use to check that it is functioning correctly and clean.
It is not permissible to operate the vehicle if the filling procedure has not been fully completed. Otherwise there may be functional limitations (degradation) or overheating.
A bleeding procedure is required after a part has been exchanged in the cooling system and/or after refilling the cooling system.

NOTE: TECHNICAL INFORMATION
Immobilization period-long fill of coolant!
Do not reuse used coolant.
When replacing and removing components which rely on the corrosion protection effect of the coolant, it is essential to change the coolant. The cooling system must therefore be emptied and refilled.
In the case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Preliminary work

Refer to DEACTIVATING ELECTRICAL SYSTEM .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to PARTIALLY REMOVING THE CHARGE AIR LINE .
Refer to REMOVING THE THROTTLE BODY .
Refer to REMOVING THE SERVOMOTOR FOR THE ECCENTRIC SHAFT .
Refer to REMOVING INTAKE SILENCER HOUSING .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THRUST FIELD .
Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
Refer to CONNECTING THE COOLANT LINE TO THE HIGH-TEMPERATURE COOLANT RADIATOR .

Precondition

Battery ground lead is disconnected.

Keep a standard hook (1) ready.

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Loosen nut (1).
Thread out positive battery cable (2) and set it aside.

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Unlock the clamp (2).
Release the coolant line (1) from the clamp (2).

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Unlock the coolant line (2) using the hook (1).
Disconnect the coolant line (2) from the cylinder head.
Catch and dispose of escaping coolant.

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Unlock the coolant line (1) and release it from the coolant expansion tank.
Feed out and remove the coolant line (1) below the intake plenum.
Replace coolant line (1).
Parts: Coolant line
Feed the coolant line (1) below the intake plenum and install it.
Connect and audibly lock the coolant line (1) onto the coolant expansion tank.

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Connect and audibly lock the coolant line (1) on the cylinder head.

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Attach the coolant line (2) with the clamp (1).

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Connect the positive battery cable (2) to the gas generator.
Tighten nut (1).

TIGHTENING TORQUE SPECIFICATION

Positive battery cable to the alternator
M8	Tightening torque	19 Nm

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Follow-up work

Refer to INSTALLING THE SERVOMOTOR FOR THE ECCENTRIC SHAFT .
Refer to INSTALLING THE THROTTLE BODY .
Refer to PARTIALLY INSTALLING THE CHARGE AIR LINE .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING INTAKE FILTER HOUSING .
Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
Refer to ACTIVATING ELECTRICAL SYSTEM .
Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to VERSION WITH ECCENTRIC SHAFT SERVOMOTOR: TEACHING IN THE END STOPS WITH THE DIAGNOSTIC SYSTEM .