Preliminary Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
4. Remove the battery tray. Refer to Battery Tray Replacement .
5. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement : Diesel  → Petrol Engines .
6. Remove the charge air cooler outlet duct. Refer to Charge Air Cooler Outlet Duct Replacement .

Special Tools

BO 38185 Hose Clamp Pliers

For equivalent tools, refer toSpecial Tools .

1

Radiator Inlet Hose

2

Heater Inlet Hose

3

Bypass Hose

4

Engine Water Outlet Adapter Bolt (Qty: 4)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
25 N·m (18 lb ft)

5

Seal

Tip
Replace with NEW seal.

6

Engine Water Outlet Adapter