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Engine Oil Cooler Coolant Pipe Replacement - Feed Opel Agila B

Engine Cooling 6 illustrations ~1158 words

Remove

  1. 1. Remove cap from coolant expansion tank
  2. 2. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

  1. 3. Drain cooling system • Place collecting container below • Open radiator drain plug • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
  2. 4. Release 2x protective panelling from front panelling • Remove 4x clip (1)
  1. 5. Release front panelling from lower front body panel • Remove 3x bolt (1)
  1. 6. Lower vehicle
  2. 7. Release front panelling from 2x front wing • Remove 2x screw (1)
  3. 8. Release front panelling from upper front body panel • Remove 2x clip (3), 4x bolt (2)
  1. 9. Remove front panelling from vehicle • Release front panelling from 2x side bracket (1) – Pull off • Disconnect 2x harness connector from 2x front fog lamp (if installed)

Note. 2x technician are required.

  1. 10. Disconnect battery negative lead • Release nut
  2. 11. Disconnect harness connector (3) from mass air flow meter (5)
  3. 12. Release cover (2) from air cleaner assembly • Release 4x screw
  4. 13. Remove air cleaner element from air cleaner assembly
  5. 14. Release coolant hose (1) from air cleaner assembly • Release clip
  6. 15. Release harness for mass air flow meter from air cleaner assembly • Release clip
  7. 16. Remove air cleaner assembly from battery tray and upper front body panel • Remove 2x bolt (4) • Pull up to release 2x locator from battery tray
  1. 17. Remove cover (1) from engine • Remove 4x bolt
  1. 18. Disconnect intercooler outlet hose (1) from intercooler (4) • Release clip
  2. 19. Disconnect intercooler inlet hose (3) from intercooler • Release clip
  3. 20. Remove intercooler from vehicle • Remove bolt (2), then lift upwards to release from 2x rubber mount
  1. 21. For vehicles without diesel particulate filter (DPF), disconnect front body harness from mixture control oxygen sensor harness • Disconnect harness connector – Release harness connector lock
  2. 22. For vehicles without DPF, release mixture control oxygen sensor harness connector from bracket • Release clip
  3. 23. For vehicles without DPF, release harness for mixture control oxygen sensor from upper front body panel • Release clip
  4. 24. For vehicles without DPF, release harness for mixture control oxygen sensor from intercooler outlet pipe • Release 2x clip (2) • Release from clip (1)
  1. 25. For vehicles without DPF, remove mixture control oxygen sensor (1) from catalytic converter • Use Socket KM-6179
  1. 26. Disconnect 4x harness connector from 4x glow plug (1)
  2. 27. Release earth strap from exhaust manifold • Remove bolt (3)
  3. 28. Remove engine lifting eye (2) from exhaust manifold • Remove bolt
  4. 29. Remove heat shield (4) from exhaust manifold • Remove bolt
  1. 30. Remove air cleaner outlet hose (1) from turbocharger • Remove 2x bolt • Release 2x clip
  1. 31. Remove oil feed pipe (1) from turbocharger and oil cooler assembly • Remove 2x bolt (2), 4x washer
  1. 32. Disconnect coolant feed pipe (1) from oil cooler assembly • Remove 2x bolt (2) • Remove gasket
  2. 33. Release 2x harness from coolant feed pipe • Release from 2x clip
  3. 34. Release coolant feed pipe from cylinder head • Remove bolt
  1. 35. Remove coolant feed pipe from thermostat hose • Remove clip (1)

Install

  1. 36. Install new coolant feed pipe to thermostat hose • Install new clip (1)
  1. 37. Connect coolant feed pipe (1) to oil cooler assembly • Clean mating surfaces • Install new gasket • Install 2x bolt (2)
  2. 38. Secure 2x harness to coolant feed pipe • Secure to 2x clip
  3. 39. Secure coolant feed pipe to cylinder head • Install bolt
  1. 40. Install oil feed pipe (1) to turbocharger and oil cooler assembly • Install 4x new washer, 2x bolt (2) 22 Nm
  1. 41. Install air cleaner outlet hose (1) to turbocharger • Install 2x bolt • Secure 2x clip
  1. 42. Install heat shield (4) to exhaust manifold • Install bolt 10 Nm
  2. 43. Install engine lifting eye (2) to exhaust manifold • Install bolt 28 Nm
  3. 44. Secure earth strap to exhaust manifold • Install bolt (3)
  4. 45. Connect 4x harness connector (1) to 4x glow plug
  1. 46. For vehicles without DPF, install mixture control oxygen sensor (1) to catalytic converter 45 Nm • Apply assembly paste to threads • Use Socket KM-6179
  1. 47. For vehicles without DPF, secure harness for mixture control oxygen sensor to intercooler outlet pipe • Secure to clip (1) • Secure 2x clip (2)
  1. 48. For vehicles without DPF, secure mixture control oxygen sensor harness connector to bracket • Secure clip
  2. 49. For vehicles without DPF, secure mixture control oxygen sensor harness to upper front body panel • Secure clip
  3. 50. For vehicles without DPF, connect front body harness to mixture control oxygen sensor harness • Connect harness connector – Secure harness connector lock
  4. 51. Install intercooler (4) to vehicle • Position intercooler to 2x rubber mount • Install bolt (2)
  5. 52. Connect intercooler outlet hose (1) to intercooler • Secure clip
  6. 53. Connect intercooler inlet hose (3) to intercooler • Secure clip
  1. 54. Install cover (1) to engine • Install 4x bolt 8 Nm
  1. 55. Install air cleaner assembly to battery tray and upper front body panel • Push down to secure 2x locator to battery tray • Install 2x bolt (4)
  2. 56. Secure harness for mass air flow meter to air cleaner assembly • Secure clip
  3. 57. Secure coolant hose (1) to air cleaner assembly • Secure clip
  4. 58. Install air cleaner element to air cleaner assembly

Note. Before installing the air cleaner element, remove all debris from the air cleaner assembly.

  1. 59. Secure cover (2) to air cleaner assembly • Secure 4x screw
  2. 60. Connect harness connector (3) to mass air flow meter (5)
  1. 61. Install front panelling to vehicle • Connect 2x harness connector to 2x front fog lamp (if installed) • Secure front panelling to 2x side bracket (1) – Push on

Note. 2x technician are required.

  1. 62. Secure front panelling to upper front body panel • Install 4x bolt (2), 2x clip (3)
  2. 63. Secure front panelling to 2x front wing • Install 2x screw (1)
  1. 64. Raise vehicle
  2. 65. Secure front panelling to lower front body panel • Install 3x bolt (1)
  1. 66. Secure 2x protective panelling to front panelling • Install 4x clip (1)
  1. 67. Lower vehicle

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

  1. 68. Fill coolant expansion tank with new coolant fluid up to maximum level mark
  2. 69. Install cap to coolant expansion tank
  3. 70. Connect battery negative lead • Secure nut 11 Nm
  4. 71. Program all volatile memories – see operation “Program Volatile Memories”
  5. 72. Start engine and allow it to run at idle speed until thermostat opens • Switch off engine

Note. Cooling system bleeds itself automatically during the warm-up phase.

  1. 73. Check and correct coolant fluid level
  2. 74. Check and correct engine oil level

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