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Contents Wiring diagrams Section: Cooling System All sections

Replace Lower Coolant Pipe Opel Combo C

Cooling System 14 illustrations ~736 words

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery
  3. 3. Raise vehicle all the way
  4. 4. Remove lower engine compartment cover / splash protection
  5. 5. Place collecting basin underneath.
  6. 6. Drain coolant from radiator • Open drain bolt • Tighten drain bolt
  7. 7. Lower vehicle all the way
  8. 8. Remove air intake pipe (1) • Unscrew 2 bolts (arrows) • Unclip wiring harness • Unclip fuel line from bracket • Detach engine vent hose – Release 2x clamp
  1. 9. Remove turbocharger charge air hose (3) • Open quick-release fitting (1) • Loosen clamp (2)
  1. 10. Detach wiring harness • Disconnect 2 wiring harness plugs • Unclip wiring harness (2x)
  2. 11. Detach coolant compensation tank • Undo clip, unclip coolant hose • Put coolant compensation tank to the side
  3. 12. Remove crash box (2) with fuel filter • Detach fuel lines with KM-976 • Unscrew 2 nuts (1)
  1. 13. Remove air intake pipe (1) from intercooler at intake manifold • Remove charge air hose – Loosen clamp (2) • Unscrew 4 bolts (3)
  1. 14. Remove oil filter housing heat shield • Unscrew 2 bolts (2) • Unscrew nut (1)
  1. 15. Remove upper coolant pipe • Release clamp (3) • Unscrew 3x bolts (1 and 2) • Remove gasket.
  2. 16. Disconnect wiring harness plug of coolant temperature sensor
  3. 17. Detach 2 coolant hoses • Release 2 clamps (1) and (2)
  1. 18. Disconnect 4 glow plug wiring harness plugs (1)
  1. 19. Remove exhaust manifold heat shield • Disconnect oil pressure switch wiring harness plug (2) • Unscrew 2 nuts (1) • Remove engine transport shackle
  1. 20. Place collecting basin underneath.
  2. 21. Remove turbocharger oil feed line (1) • Unscrew 2 banjo bolts (arrows)
  1. 22. Detach turbocharger (2) with catalytic converter (3) from exhaust manifold • Unscrew 3 bolts (1)

Note. No gasket installed

  1. 23. Raise vehicle all the way
  2. 24. Detach exhaust system from catalytic converter • Release clamp

Note. Suspend from underbody.

  1. 25. Detach turbocharger oil return line (1) from cylinder block • Unscrew 2 bolts
  1. 26. Detach catalytic converter (1) from transmission • Unscrew 1x bolt (2)
  1. 27. Remove turbocharger with catalytic converter
  2. 28. Remove lower coolant pipe (1) • Unscrew 2 bolts (2)
  1. 29. Clean sealing surface • At cylinder block

Install

  1. 30. Install lower coolant pipe • Replace seal ring • Insert coolant return pipe in cylinder block • Tighten 2 bolts 9 Nm

Important. Make sure the seal ring is not displaced during installation.

  1. 31. Fit turbocharger with catalytic converter
  2. 32. Attach catalytic converter to transmission • Tighten bolt 25 Nm
  3. 33. Attach exhaust system to catalytic converter • Fasten clamp
  4. 34. Attach turbocharger oil return line at cylinder block • Replace gaskets • Tighten 2 bolts 9 Nm
  5. 35. Install lower engine compartment cover / splash protection • Tighten 3 bolts • Install clip
  6. 36. Lower vehicle all the way
  7. 37. Attach turbocharger to exhaust manifold • Tighten 3 new bolts 25 Nm
  8. 38. Attach exhaust manifold heat shield • Insert engine transport shackle • Tighten 2 nuts 15 Nm • Connect wiring harness plug of oil pressure switch
  9. 39. Connect 4 wiring harness plugs for glow plugs
  10. 40. Install turbocharger oil feed line • Replace 4x seal ring • Tighten 2 banjo bolts 12 Nm
  11. 41. Install upper coolant pipe • Replace gasket • Tighten 3 bolts 9 Nm • Fasten clamp
  12. 42. Attach 2x coolant hose • Secure 2x clamp
  13. 43. Connect wiring harness plug of coolant temperature sensor
  14. 44. Install oil filter housing heat shield • Tighten 2 bolts • Tighten nuts
  15. 45. Install air intake pipe of intercooler to intake manifold • Replace gasket • Tighten 4 bolts • Attach charge air hose. – Fasten clamp 3.5 Nm
  16. 46. Install crash box • Tighten 2 nuts 25 Nm • Attach fuel lines
  17. 47. Attach coolant compensation tank • Attach clip, clip in coolant hose
  18. 48. Attach wiring harness • Connect 2 wiring harness plugs • Clip in wiring harness (2x)
  19. 49. Install air intake manifold • Attach 2 clamps 3.5 Nm • Tighten 2 bolts • Attach wiring harness • Install hose – Fasten clamp
  20. 50. Install turbocharger charge air hose • Fasten clamp • Engage quick release fitting
  21. 51. Check engine oil level, if necessary correct. • Observe specified engine oil quantity
  22. 52. Connect battery • Attach ground clamp to ground terminal – Tighten nuts
  23. 53. Top up coolant
  24. 54. Program volatile memory
  25. 55. Close bonnet

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