Table of contents: Removal ↓ Installation ↓
Removal
Drain the coolant. Remove the coolant hoses "arrows" from the coolant expansion tank and lay the coolant hose loosely on top.
Disconnect the plug connector "1" of the low coolant level indicator sensor "F66". Unscrew the nut "arrow" and remove the coolant expansion tank.
Place the B+ wire loosely on the holder "1". Place the engine wiring harness "2" loosely on the support "arrow" and press it to the side.
Caution! Risk of damage to cable locks. Do not remove cable locks from the shift rod lever and intermediate lever. Removed cable locks must be replaced.
Unlock the selector and shift cable lock as described below: Pull the safety mechanism on the shift drive cable "arrow A" forward as far as it will go. Turn the movable sleeve "arrow B" as far as it will go and lock it. Pull the selector and shift cable out of the cable lock. Remove the cap "3" above the lock washer. Remove the lock washer "2" and the automatic transmission selector. Ignore pos. "1, 4".
Unscrew the right drive shaft from the axle shaft with the gearbox flange. Unscrew the screws "arrows" and remove the intake manifold support. Disconnect connector "2". Ignore position "1" and "arrows".
Remove the coolant hoses "arrows".
Disconnect connector "1" of coolant temperature sensor "G62". Ignore pos. "2". Release the wiring harness on the rear coolant pipe.
Install the tray for the service cranes "VAS 6208" under the engine. Unscrew the bolts "arrows" and carefully pull out and remove the thermostat housing with the rear branch pipe of the cooling system from the cylinder block.
Remove clamp "2" and remove the rear cooling system pipe "3" from the housing "1" of the thermostat "arrow".
Installation
Installation is in reverse order, replacing the gaskets and O-rings. Use clamps of the appropriate series to secure all hose connections.
Insert the rear coolant hose with a new sealing ring "4" into the thermostat housing.
Protrusion "3" must be inserted into U-shaped recess "2". Fix the cooling system pipe with clamp "1". Clean or polish the sealing surface under the O-ring in the cylinder head. Moisten the O-ring with concentrate. Install the intake manifold pipe. Install the right axle joint. Install and adjust the selection and shift cables. Fill with coolant.