Radiator Expansion Tank - Broken Return Line
90audi03Applies To: 5000, ALL 1984-1988 m.y.
Subject: Broken Radiator Expansion Tank Return Line Connection, Repairing
Number: Group:
90-03
February 9, 1990 19
Engine
Broken radiator expansion tank return line connection, repairing
Parts required
Description Part Number Quantity
Return line connection 200 121 002 1
Chem-Weld 200 121 003 1
Epoxy Glue
Drill with 9.5 mm locally available 1
(3/8 in.) drill bit
Hacksaw locally available 1
Antifreeze/Coolant ZVW 237 102 As required
CAUTION
Part numbers are for reference only. Always check with your Parts Department for latest information.
^ drain radiator sufficiently to lower fluid level below broken return line connection
^ using hacksaw, cut off remaining broken return line connection tube flush with radiator
^ damaged connection must be completely removed
^ enlarge hole with drill
^ DO NOT drill through
^ using hacksaw, cut off threads of replacement return line connection in middle (as shown)
^ apply epoxy glue to threaded end of connection
^ using replacement connection as a tap, carefully thread connection into radiator
^ carefully tighten connecticn until base touches radiator (arrow)
^ DO NOT over tighten
^ apply remaining epoxy glue to area where connection touches radiator
^ allow epoxy to set before installing expansion tank return hose
^ approx. 1 hour
^ reinstall all components in reverse order of removal
^ top off radiator with antifreeze/coolant as required
Broken radiator
expansion tank return
line connection, Diag. Quality
repairing Check Repair Check
Labor Op. 1970511 - 40 TU 10 TU