PRE-RELEASE
Coolant pipe, removing a fitting
| Coolant pipe, removing a fitting |
| To remove |
| 1. |
Open the bonnet
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| 2. |
Disconnect the battery.
Remove the ground cable. |
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| 3. |
Remove the engine protection cover.
Unscrew the lid on the oil filler connection 2x Unscrew Screw on the lid on the oil filler connection |
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| 4. |
Remove the air cleaner casing (1)
Pull off the cable set connector (2) - Heating conductor-mass air flow sensor Undo the cable set Detach the engine ventilation hose (3) Detach the intake hose (4) 
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| 5. |
Raise the car
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| 6. |
Remove the wing liner
4x Undo the bolt 
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| 7. |
Remove the multi-belt
Turn the multi-belt tension device in the direction of the arrow Use KM-913-A (2) or a 15mm flex-head spanner. Insert KM-6130 (1) or a 4mm drift. Mark the direction of rotation 
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| 8. |
Dismantle the engine management system cable set
4x Pull off the cable set connector - Lambda sensor, catalytic converter (1), oil pressure switch (2), crankshaft position sensor (3), dynamic oil level check (4) Undo the cable set - 2x Holder 
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| 9. |
Undo the generator
Undo the nut |
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| 10. |
Remove the intake manifold support
Undo the screw at the top Undo the screw at the bottom |
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| 11. |
Lower the car
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| 12. |
Drain the coolant
Place a receptacle underneath Open the drain screw (arrow) Warning: observe safety regulations and country-specific stipulations 
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| 13. |
Lower the fuel pressure
Use KM-J-34730-91 or 83 94 744 Adapter, fuel pressure gauge Unscrew the test connection protective cap on the fuel rail 
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| 14. |
Remove the fuel line
Use KM-796-A or 83 95 261 Fuel line tool (1) Undo the fuel line holder - Unscrew the nut Close the fuel line Use KM-807 
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| 15. |
Remove the fuel line
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| 16. |
Remove the evap canister purge valve
Undo the bolt Pull off the fuel evaporation line Pull off the cable set connector |
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| 17. |
Detach the engine ventilation hose
from camshaft cover |
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| 18. |
Dismantle the engine management system cable set
13x Pull of cable set connector - Compressor (9), coolant temperature sensor (8), air conditioning pressure sensor (10), camshaft position sensor, throttle valve module (1), intake manifold solenoid valve, 2x engine control module (2), knock sensor (3), combination connector (4), EGR valve (5), DIS ignition module (6), lambda sensor, fuel regulator (7) Detach the ground cable - Undo the screw Undo the cable set 
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| 19. |
Remove the fuel rail
2x Undo the bolt (arrows) Instruction: pull out with the injectors 
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| 20. |
Undo the throttle valve module preheating line
Detach the preheating hose (2) - from the throttle valve module 2x Unscrew Undo the camshaft sensor cable set connector (1) |
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| 21. |
Detach the throttle valve preheating return hose (3) from the throttle valve module
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| 22. |
Detach the brake servo vacuum line
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| 23. |
Detach the warm water return hose from the warm water coolant pipe
2x Undo the holder |
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| 24. |
Undo the generator mounting
Unscrew the bolt, stud Instruction: Swing back the generator |
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| 25. |
Remove the intake manifold
7x Unscrew the nut (arrows) Remove the seal 
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| 26. |
Detach the warm water inlet hose (2) from the coolant pipe
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| 27. |
Undo the cable set
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| 28. |
Detach the coolant equalising container coolant hose (3) form the coolant pipe
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| 29. |
Detach the bottom coolant hose (1) from the coolant pipe
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| 30. |
Undo the coolant pipe
Undo the bolt (arrow) |
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| 31. |
Remove the coolant pipe (3)
2x Remove the coolant hose - Remove the middle coolant hose (2) - Coolant hose coolant pipe coolant connection (1) 
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| To fit |
| 1. |
Fit the coolant pipe
2x Fit the coolant hose - Remove the middle coolant hose - Coolant hose coolant pipe coolant connection |
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| 2. |
Fasten the coolant pipe
Tighten the bolt - Tightening torque 60 Nm |
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| 3. |
Fit the bottom coolant hose
Screw on the lid on the oil filler connection |
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| 4. |
Fit the coolant equalising container coolant hose
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| 5. |
Fasten the cable set
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| 6. |
Fit the warm water inlet hose
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| 7. |
Clean sealing surfaces. Cylinder head, intake manifold
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| 8. |
Fit the intake manifold
Instruction: Change the seal, nuts 7x Tighten nut - Tightening torque 20 Nm |
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| 9. |
Fit the brake servo vacuum line Instruction: The connection must snap audibly in place
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| 10. |
Fit the generator mounting
Tighten the bolt, stud - Tightening torque 20 Nm |
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| 11. |
Fit the hot water return hose
2x Close the clamp |
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| 12. |
Fit the throttle valve preheating return hose
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| 13. |
Fit the throttle valve module preheating line
2x Tighten bolt - Tightening torque 8 Nm Fasten the camshaft sensor cable set connector |
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| 14. |
Fit the fuel rail
Instruction: Put in together with the injectors, the engine management system cable set 4x Change the injector sealing ring 2x Tighten bolt - Tightening torque 8 Nm |
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| 15. |
Fit the engine management system cable set
Pull the cable set 13x Fasten the cable set connector Fit the ground cable. Fasten the cable set |
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| 16. |
Fit the engine vent hose.
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| 17. |
Fit the evap canister purge valve
Tighten the bolt Fasten the fuel evaporation line Connect cable set connector |
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| 18. |
Fit the fuel line
Tighten the nut Instruction: Hold with an open spanner - Tightening torque 15 Nm |
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| 19. |
Fit the fuel line
Fit the fuel line holder - Tighten the nut - Tightening torque 15 Nm |
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| 20. |
Raise the car
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| 21. |
Close the coolant drain screw
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| 22. |
Fit the intake manifold support onto the intake manifold
- Tighten the bolt - Tightening torque 20 Nm on the engine block - Tighten the bolt - Tightening torque 35 Nm |
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| 23. |
Fasten the generator
Tighten the nut - Tightening torque 35 Nm |
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| 24. |
Fit the engine management system cable set
4x Fasten the cable set connector 2x Fasten the cable set |
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| 25. |
Fit the multi-belt
Instruction: Observe the rotation direction and fitting position Loosen the multi-belt tensioning device - Use KM-913-A or a 15 mm flex head spanner Remove KM-6130 or 4mm drift. 
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| 26. |
Fit the multi-belt guard
4x Tighten bolt |
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| 27. |
Lower the car
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| 28. |
Fit the air filter housing
Fit the intake hose Fit the engine vent hose Connect cable set connector Fasten the cable set |
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| 29. |
Fit the top engine cover
Unscrew the lid on the oil filler connection Tighten the bolts Screw on the lid on the oil filler connection |
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| 30. |
Fill with coolant
Instruction: Fill and bleed the cooling system - See Cooling system, filling and bleeding . Observe the prescribed amount of coolant |
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| 31. |
Connect the battery.
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| 32. |
Close the bonnet
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| 33. |
Program erased memories
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