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Combustion circulation actuator (403)

Combustion circulation actuator (403)

Important

Always use wing covers when working in the engine bay.


To remove


1. Remove the engine cover and insulation. Disconnect the negative battery lead.

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



2. Loosen the coolant expansion tank cap to release any pressure.

3. Raise the car.

4. Remove the lower engine cover.


5. Place a receptacle under the radiator. Connect a hose to the radiator and drain the radiator. Close the tap.


6. Lower the car to the floor.

7. Detach the turbocharger delivery hose from the pipe and throttle body.


8. Place a receptacle under the engine to collect the coolant.


9. Detach the coolant hose from the coolant pipe and remove the nut from the pipe clamp.

10. Detach the coolant hose from the thermostat housing.


11. Remove the nuts holding the coolant pipes to the starter motor bracket. Move the pipes aside slightly to make room for the vacuum reservoir.

12. Detach the vacuum hoses from the vacuum reservoir. Remove the vacuum hose bolts from the camshaft housing and oil trap bracket.


13. Detach the EGR valve connector.

14. Disconnect the front hoses from the vacuum pipes. Remove the vacuum pipes.

15. Remove the vacuum reservoir.


16. Disconnect the upper hoses from the oil trap. The right-hand hose has a quick coupling. Hold the black plastic ring and pull the coupling upward.

17. Remove the nuts and bolts holding the oil trap bracket in place and move it aside.

18. Remove the actuator. Carefully prise the control arm off the ball joint. Unplug the actuator's connector.



To fit


1. Plug and fit in the actuator. Press the control arm onto the ball joint using suitable pliers.


2. Reposition the oil trap bracket. Fit the nuts and bolts.


3. Attach the upper hoses of the oil trap.

4. Fit the vacuum chamber. Note that the small hose connection is the upper connection.

5. Fit the vacuum pipes to the camshaft housing and connect the hoses to the vacuum chamber.


6. Plug in the EGR valve connector.

7. Fit the coolant pipes to the starter motor bracket.


8. Attach the coolant hose to the coolant pipe.


9. Attach the coolant hose to the thermostat housing.


10. Fit the nut to the pipe clamp.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


11. Fit the turbocharger delivery hose to the turbocharger delivery pipe and the throttle body.


12. Raise the car.

13. Fit the lower engine cover.


14. Lower the car to the floor.

15. Pressure test, see Cooling system, pressure testing and fill with coolant, see Bleeding the cooling system .

16. Reconnect the negative cable to the battery.


17. Remove the wing covers and restore the car's electrical functions, see After disconnecting the battery .

18. Connect an exhaust hose and start the engine. Check for leaks. Connect the diagnostic tool and clear any diagnostic trouble codes.

19. Fit the insulation and upper engine cover.