"VCC-128865 EN 2009-05-19"

Replacing coolant
Draining the coolant from the radiator and the
engine
Remove the cap from the expansion tank.
Open the radiator drain cock. Install one hose
on the nipple to lead off the coolant.
Close the cock when the coolant is drained.
When draining the coolant from the engine,
slacken off the plug at the rear of the engine.
Close the plug after draining.

Filling with coolant

Fill the cooling system via the expansion tank.
The total volume of coolant is approximately
6.3 litres.
Turbocharged engines:Open the nipple in the
lower engine coolant hose. Close the nipple
when only coolant comes out.
Run the engine to operating temperature and
top up the coolant if necessary.
Check for leaks.

Replacing the coolant pump

Draining the coolant
Remove:
- the cap for the expansion tank
- the splash guard under the engine.
Position a container under the engine drain
cock. Drain the engine coolant.
Avoid skin contact with the coolant.
Transfer the container to the radiator drain cock.
Drain off the remaining coolant.
Close the nipples. Install the splash guard under
the engine.
Removing the auxiliaries belt

Slacken off the auxiliaries belt by turning the

screw on the tension reel clockwise.
Remove the auxiliaries belt.

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 "VCC-128865 EN 2009-05-19"

Removing the timing covers

Remove:
- the upper timing cover
- the front timing cover.

Installing the lifting beam and lifting hook

Install the lifting beam and the lifting hook
according to Replacing the timing belt .
Removing the right-hand engine mounting
Remove the right engine mounting according to
Replacing the timing belt .
Position the engine according to the marking
See Replacing the timing belt .
Removing the timing belt
Remove the timing belt according to Replacing
the timing belt .
Removing the coolant pump

- Remove the screws

- tap the pump wheel using the shaft of a
hammer. Remove the pump
- clean the gasket faces thoroughly.

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 "VCC-128865 EN 2009-05-19"

Installing the coolant pump

Install:
- a new gasket
- a new pump.
Tighten the screws. Tighten to 17 Nm.

Installing the timing belt

Install the new belt in the following order:

- crankshaft
- the idler pulley
- intake camshaft
- exhaust camshaft
- water pump
- belt tensioner.

Tension the timing belt

Note! This adjustment is to be made with a cold
engine. Suitable temperature is approximately
20°C/67°F.
At higher temperatures (with the engine at
operating temperature or a high outside
temperature for example) the indicator is further
to the right.
The illustration shows the position of the
indicator at different engine temperatures.

- Carefully turn the crankshaft clockwise until

the timing belt is tensioned. The belt must be
tensioned between the intake camshaft
pulley, the idler pulley and the crankshaft
Hold the belt tensioner centre screw secure.

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 "VCC-128865 EN 2009-05-19"

- Hold the belt tensioner centre screw secure.

Turn the belt tensioner eccentric counter-
clockwise until the tensioner indicator passes
the marked position.
Then turn the eccentric back so that the
indicator reaches the marked position in the
centre of the window
- Hold the eccentric securely. Tighten the
centre screw. Tighten to 20 Nm.
Check that the indicator is in the correct
position.
Check

Checking markings
- Press the belt to check that the indicator on
the tensioner moves easily
- Install the upper timing cover
- Turn the crankshaft two turns. Check that the
markings on the crankshaft and camshaft
pulley correspond.
Note! Check that the indicator on the belt
tensioner is within the marked area.

Installing timing covers

Install:
- the lower timing cover
- the front timing cover. Tighten to 12 Nm
- the auxiliaries belt.

Installing the right engine mounting

Screw the engine mounting into place on the

engine. Tighten to 67 Nm.
Install:
- the screws on the bracket for the bodywork.
Tighten to 50 Nm
- the servo reservoir.

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 "VCC-128865 EN 2009-05-19"

Finishing

Remove the lifting beam and lifting hook.

Install:
- the metal bracket for the power steering hose
on the rotation protection for the auxiliaries
belt
- the front wheel according to Replacing front
brake pads
- the auxiliaries belt.

Checking work
Function test:
- runs the engine to normal operating
temperature until the thermostat opens
- top up the cooling system if necessary.
Check for leaks.

Checking/replacing thermostat
Draining coolant
See Replacing coolant .
Drain off approx. 2 litres of coolant.
Remove thermostat
Turbo: remove throttle body cover.
Remove the fuelrail cover.
Remove the upper distribution cover.
Remove the thermostat housing cover (Torx 40)
and remove the thermostat and gasket.

Checking thermostat
The thermostat can be checked in hot water.
In water at the temperature at which the
thermostat opens, the thermostat should open
fully within two minutes.
Mark: 90
Opens at: 90°C
Wide open at: 105°C

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 "VCC-128865 EN 2009-05-19"

Install thermostat

Clean the surfaces of the thermostat housing.

Install a new gasket to the thermostat.
Install the thermostat in the housing. Install the
cover and tighten the housing cover. Tighten to
17 Nm.
Fit the upper distribution cover.
Fit the fuelrail cover.
Turbo: fit cover throttle body.
Fill with coolant, see Replacing coolant .

Replacing engine coolant temperature (ECT) sensor

Removing engine coolant temperature (ECT)
sensor

Preparations
- Remove expansion tank cap.
- open the valve on the right underside of the
radiator, use a hose to collect the coolant
(cars with air conditioning (A/C): partially
remove the splash guard under engine).
- Drain two liters of coolant.
- Close valve.
Removing thermostat housing lid
- Remove fuel rail cover.
- Remove upper distribution cover, see
Replacing cover engine top side .
- Remove thermostat housing lid (two screws)
and move the cover to the side.
Removing engine coolant temperature (ECT)
sensor
- Remove connector from bracket.
- Disconnect connector.
- Remove engine coolant temperature (ECT)

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 "VCC-128865 EN 2009-05-19"

sensor and sealing ring.

Installing engine coolant temperature (ECT)
sensor

- Clean mating surfaces.

- Install a new sealing ring on the engine
coolant temperature (ECT) sensor.
- Install the engine coolant temperature (ECT)
sensor and tighten to 10 Nm.
- Reconnect connector.
- Reinstall connector on bracket.
Installing thermostat housing lid
- Clean mating surfaces.
- Apply a new gasket to the thermostat.
- Secure the thermostat housing and tighten to
17 Nm.
Note! Refill the coolant, run the engine to
operating temperature and top up as necessary.
Function test and check for any leakage.
Check for leakage and reinstall fuel rail cover
and upper distribution cover, see Replacing
cover engine top side .
Connect wiring to connector and fit to bracket.

Replacing radiator
Note! As the illustrations in this service
information are used for different model years
and / or models, some variation may occur.
However, the essential information in the
illustrations is always correct.
Conditions
- Drain the coolant. See Replacing coolant
- Remove the front engine cover
- Remove the charge air cooler (CAC), see
Replacing the charge air cooler (CAC) .
Removing the radiator
Remove the upper and lower radiator hoses.
Manual gearboxs: Remove the radiator together
with the charge air cooler (CAC).
Automatic gearbox: Move the charge air cooler
(CAC) as far to the right as possible. Press out
the oil cooler.
Disconnect the radiator. Remove it above the

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charge air cooler (CAC) hose connector.

Transferring components
Transfer the four radiator mountings to the
radiator.
Installing the radiator
Manual gearboxs:
- Install the radiator on the charge air cooler
(CAC). Install the unit assembly. See
Replacing the charge air cooler (CAC) .
Automatic gearbox:
- Install the charge air cooler (CAC). Press the
oil cooler into place
- Install the radiator at the top right-hand first.
Then install the radiator over the oil cooler
connections
- Position the oil cooler. Check the alignment of
the oil cooler
- Position the radiator on the charge air cooler
(CAC)
- Remove the charge air cooler (CAC), see
Replacing the charge air cooler (CAC) .
- Install the front engine cover
- Fill the cooling system. See Replacing
coolant .

Replacing drive belt/belt tensioner auxiliary system idler pulley

Removing drive belt
Use a 15 mm socket wrench on the belt
tensioner and de-tension the belt.
Remove the belt.

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 "VCC-128865 EN 2009-05-19"

Replacing belt tensioner idler pulley

Remove the bolt and the tensioner idler pulley.
Fit the new tensioner idler pulley.
Tighten the bolt to 20 Nm.
Check the poly V-belt carefully and replace if
necessary.

Replacing belt tensioner

Remove the tensioner idler pulley, see
Replacing belt tensioner idler pulley .
Remove the centre bolt at the back and remove
the belt tensioner.
Install the new belt tensioner with the cut-out
over the cam.
Install the central bolt. Tighten to 20 Nm.
Install the tensioner idler pulley, see Replacing
belt tensioner idler pulley .

Installing drive belt

Route the belt around the crankshaft, then
around the AC compressor, guide pulley,
alternator and power steering pump.
Lift the belt tensioner up and lay the belt on it
(the dotted line shows the route of the belt in
cars without AC).
Check that everything works correctly.

Replace engine coolant fans, turbo engines

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 "VCC-128865 EN 2009-05-19"

Note! Remove the complete unit with both of the

fans if the car is equipped with airco.
Remove at the top side

Remove:
- the front engine-bay cover.
- mark the EVAP hose and remove it from the
canister purge (CP) valve.
- the connector from the intake air temperature
(IAT) sensor on the charge air cooler (CAC)
(undo wiring from the shroud).
- the connector from the right side fan.
- the two bolts at the top from the unit.
Raise the car.
Remove from the underneath
Remove:
- both the engine splash guards.
- the longitudinal beam, see Removing
turbocharged engines with the gearbox .
Remove complete unit

Remove:
- the connector fan at the left side.
- the EVAP hose out of the clamp.
- the two bolts from underneath.
- the charge air cooler (CAC) hose.
- move the complete unit downwards and
move the hoses sidewards.

Removing fan blade and motor

- Remove the nut or clip.

- Pull off the fan blade.
- Pull the cable out of the clamping and the
connector.
- Remove the nuts or bolts and take the fan
motor out.

Install fan motor and blade

- Install the fan motor and tighten the bolt or

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nut to 10 Nm.
- Route the cables and fit the connectors.
- Install the fan blade and secure it with the clip
or nut. tightening torque 10 Nm.
- Route the wiring and fit the connectors.

Install complete unit

- Install the unit carefully in the correct position

at the radiator side.
- Install the bolts at the underside. Tighten to
10 Nm.
- Clean the connections and connect the
charge air cooler (CAC) hose.
- Open the clamps and fit the EVAP hose.
- Connect the connector.

Install from underneath

- The longitudinal beam, see Turbocharged
engine assembly with the transmission,
installing .
- Both engine splash guards.
Tighten and fit parts from the top

- Position the holder and fit the two bolts.

Tighten to 10 Nm.
- Install the EVAP valve and fit the connector.
- Connect the fan connectors.
- Tighten the cables and tie up.
- Connect the cable of the intake air
temperature (IAT) sensor.
Check the function and install the front engine-
bay cover.

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