Remove
- 1. Disconnect battery negative lead • Release nut
- 2. Remove cap from radiator
- 3. Raise vehicle
Important. Observe the relevant environmental regulations when disposing of used coolant.
- 4. Drain cooling system • Place collecting container below • Open radiator drain plug (1) • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
- 5. Lower vehicle
- 6. Remove coolant expansion tank (1) from battery tray • Disconnect overflow hose from radiator – Release clip • Install 2x new blanking plug • Slide off
- 7. Remove cap from coolant expansion tank
Important. Observe the relevant environmental regulations when disposing of used coolant.
- 8. Drain any fluid from coolant expansion tank • Clean inside of coolant expansion tank; flush it well with clean water and drain
- 9. Install coolant expansion tank (1) to battery tray • Slide on • Remove 2x blanking plug • Connect overflow hose to radiator – Secure clip
- 10. Release air cleaner assembly (1) from cylinder head cover • Pull off to release 2x rubber locator • Remove cover and air cleaner element from air cleaner assembly – Release 2x clip (2), 2x locator
- 11. Disconnect harness connector (1) from fuel tank evaporation solenoid valve
- 12. Disconnect harness connector from mass air flow (MAF) meter (1)
- 13. Release harness for fuel tank evaporation solenoid valve and engine harness from air cleaner assembly • Release 2x clip
- 14. Release fuel tank evaporation solenoid valve (3) from air cleaner assembly (2) • Remove bolt
- 15. Release fuel pipe assembly from air intake hose • Pull off
- 16. Disconnect hose (5) for fuel tank evaporation solenoid valve from intake manifold • Release clip • Install 2x new blanking plug
- 17. Disconnect air intake hose from throttle valve module • Release clip (1)
- 18. Disconnect engine breather hose (6) from cylinder head cover • Release clip • Install 2x new blanking plug
- 19. Remove air cleaner assembly from intake manifold • Remove bolt (4)
- 20. Disconnect harness connector (1) from throttle valve module, then move to one side
- 21. Disconnect inlet and outlet hose (1) from throttle valve module • Release 2x clip • Install 4x new blanking plug
- 22. Remove throttle valve module (2) from intake manifold • Remove 2x nut (3), 2x bolt (4)
- 23. Remove rubber seal (1) from intake manifold • Pull off
Note. The rubber seal has its own pull tag attached.
- 24. Disconnect hose (1) for brake servo from intake manifold • Release clip • Install 2x new blanking plug
- 25. Disconnect heater inlet hose from bracket for intake manifold • Release from clip (1) – Pull off
- 26. Disconnect engine vent valve hose from intake manifold • Release from heater matrix outlet hose – Release from clip • Release clip (2) • Install 2x blanking plug
- 27. Disconnect harness connector (3) from manifold absolute pressure (MAP) sensor
- 28. Release harness for MAP sensor from intake manifold • Release clip
- 29. Remove intake manifold bracket (1) from intake manifold • Remove bolt
- 30. Remove intake manifold from intake manifold spacer • Remove 2x nut (1), 2x bolt (2)
- 31. Remove rubber seal from intake manifold • Pull off
Note. The rubber seal has its own pull tag attached.
- 32. Disconnect heater matrix outlet hose from water transfer pipe, then move to one side • Release clip (2) • Install 2x new blanking plug
- 33. Release outlet hose from water transfer pipe • Release clip (1) • Install 2x new blanking plug
- 34. Disconnect lower radiator hose (2) from water transfer pipe • Release clip • Install 2x new blanking plug
- 35. Disconnect heater matrix inlet hose (3) from thermostat housing assembly, then move to one side • Release clip • Install 2x new blanking plug
- 36. Release harness for oxygen sensor from water transfer pipe • Release clip (1)
- 37. Remove water transfer pipe from thermostat housing assembly and engine block • Remove 2x bolt (1, 2)
- 38. Remove seal ring from water transfer pipe • Prise off
- 39. Remove intake manifold spacer from cylinder head • Remove bolt (1) • Remove gasket
- 40. Clean mating surfaces of cylinder head and intake manifold spacer for new intake manifold gasket. (cleaning both surfaces)
Install
- 41. Install intake manifold spacer to cylinder head • Install new gasket • Install bolt (1)
- 42. Install water transfer pipe to thermostat housing assembly and engine block • Install new seal ring – Apply suitable lubricant • Install 2x bolt (1, 2)
- 43. Secure harness for oxygen sensor to water transfer pipe • Secure clip (1)
- 44. Connect heater matrix inlet hose (3) to thermostat housing assembly • Remove 2x blanking plug • Secure clip
- 45. Connect lower radiator hose (2) to water transfer pipe • Remove 2x blanking plug • Secure clip
- 46. Connect outlet hose to water transfer pipe • Remove 2x blanking plug • Secure clip (1)
- 47. Connect heater matrix outlet hose to water transfer pipe • Remove 2x blanking plug • Secure clip (2)
- 48. Clean mating surfaces of intake manifold and intake manifold spacer for new rubber seal (cleaning both surfaces)
- 49. Install new rubber seal to intake manifold • Apply suitable lubricant to rubber seal, then push on
- 50. Install intake manifold to intake manifold spacer • Install 2x nut (1), 2x bolt (2)
- 51. Install intake manifold bracket (1) to intake manifold • Install bolt
- 52. Secure harness for MAP sensor to intake manifold • Secure clip
- 53. Connect harness connector (3) to MAP sensor
- 54. Connect engine vent valve hose to intake manifold • Remove 2x blanking plug • Secure clip (2) • Connect engine vent valve hose to heater matrix outlet hose – Secure clip
- 55. Connect heater matrix inlet hose to bracket (1) for intake manifold • Secure to clip – Push on
- 56. Connect hose (1) for brake servo to intake manifold • Remove 2x blanking plug • Secure clip
- 57. Clean mating surfaces of intake manifold and throttle valve module assembly. (cleaning both surfaces)
- 58. Install new rubber seal (1) to intake manifold • Apply suitable lubricant to rubber seal, then push on
- 59. Install throttle valve module (2) to intake manifold • Install 2x nut (3), 2x bolt (4) 23 Nm
- 60. Connect inlet and outlet hose (1) to throttle valve module • Remove 4x blanking plug • Secure 2x clip
- 61. Connect harness connector (1) to throttle valve module
- 62. Install air cleaner assembly to intake manifold • Install bolt (4)
- 63. Connect engine breather hose (6) to cylinder head cover • Remove 2x blanking plug • Secure clip
- 64. Connect air intake hose to throttle valve module assembly • Secure clip (1)
- 65. Connect hose (5) for fuel tank evaporation solenoid valve to intake manifold • Remove 2x blanking plug • Secure clip
- 66. Secure fuel pipe assembly to air intake hose • Push on
- 67. Secure fuel tank evaporation solenoid valve (3) to air cleaner assembly (2) • Install bolt
- 68. Secure harness for fuel tank evaporation solenoid valve and engine harness to air cleaner assembly • Secure 2x clip
- 69. Connect harness connector to MAF meter (1)
- 70. Connect harness connector (1) to fuel tank evaporation solenoid valve, then secure to 2x clip
- 71. Install air cleaner element and cover to air cleaner assembly (1) • Secure cover to air cleaner assembly – Secure 2x locator, then secure 2x clip (2)
- 72. Secure air cleaner assembly to cylinder head cover • Push on to secure 2x rubber locator
Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.
- 73. Fill coolant expansion tank with new coolant fluid up to maximum level mark
- 74. Install cap to coolant expansion tank
- 75. Fill radiator with new coolant fluid up to bottom of radiator filler neck
- 76. Install cap to radiator
- 77. Connect battery negative lead • Secure nut 11 Nm
- 78. Program all volatile memories – see operation “Program Volatile Memories”
- 79. Start engine and allow it to run at idle speed until thermostat opens
Note. Cooling system bleeds itself automatically during the warm-up phase.
- 80. Switch off engine
- 81. Check and correct coolant fluid level