Upper Coolant Pipe

Upper Coolant Pipe

Special tools, testers and auxiliary items required

• Socket 14 mm (3150)

• Torque Wrench (V.A.G 1331)

• Ratchet (V.A.G 1331/1)

• Open End Wrench Socket 17 mm (V.A.G 1331/2)

• Open End Wrench Socket 17 mm (V.A.G 1331/8)

• Socket 14 mm (T40055)

Removing

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Remove upper section of intake manifold.

CAUTION!
Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure.

CAUTION!
The crankcase ventilation must not be removed.

- Remove left cylinder head cover and lay aside with crankcase ventilation hose connected. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover.

- Remove the high-pressure line, thereby removing bolts and union nuts - 1 through 6 -.





- Place a rag under the coolant pipe to catch the escaping coolant.





- Disconnect coolant hose - 3 - from coolant pipe.

- Remove bolts - 1 - and - 2 - and pull coolant pipe rearward and out of the cylinder block - arrow -.

Installing

Installation is in reverse order of removal, note the following:

• Replace O-ring.

• During installation, all cable ties must be re-installed at the same location.

- Clean and/or smooth O-ring sealing surface before installing.

- Coat a new O-ring with coolant and slide it onto the coolant pipe.

- First tighten the union nuts - 1 -, - 4 - and - 5 - for the high pressure lines by hand and then the lines - 2 -, - 3 - and - 6 -.





- Make sure the high-pressure lines are seated free of stress.

- To fasten the high-pressure line (14 mm) at fuel rail use the Torque Wrench (V.A.G 1331) with 14 mm Open End Wrench Socket (V.A.G 1331/8).





- To fasten the high-pressure line (17 mm) at fuel rail use the Torque Wrench (V.A.G 1331) with 17 mm Open End Wrench Socket (V.A.G 1331/2).





- To fasten the high-pressure line (17 mm) at high pressure pump use the Torque Wrench (V.A.G 1331) with ratchet (V.A.G 1331/1) and Socket 17 mm (T40055).





- Install intake manifold upper section.

- Fill with coolant => [ Filling ] Procedures.

Tightening Specifications