Coolant Line/Hose: Service and Repair
Removing and installing coolant hoses - GT3
Removing coolant hoses
1. Open engine compartment lid.
2. Put on protective covers.
Warning: Data loss!
- Before disconnecting the battery, find out the theft codes.
- Before disconnecting the battery, read out the fault memory.
3. Open the front luggage compartment. Subsequently disconnect and remove the negative terminal (a/f 10) of the battery.
Caution:
Risk of damage if the vehicle is raised incorrectly!
- Raise the vehicle at the prescribed jacking points
- Raise the vehicle at the engine by means of a workshop jack so that the swivel arms of the hoist passes underneath the kick plates without damage.
4. Raise the vehicle to working height with the lifting platform.
5. Pull off electrical wire connector of the hot film mass air flow meter. To do this, push the plug on the grooved surface at the sides and pull the plug off in an upward direction. Open the omega clip on the right side of the air cleaner housing and take out the electrical wire of the hot film mass air flow meter. Re-close the omega clip for the removal (risk of breakage).
- Unscrew the fastening screw M6 x 34 (a/f 13) at the rear of the air cleaner housing.
6. Before removing or relieving the drive belt, loosen the drive pulley of the hydraulic pump. Unscrew three hexagon-head bolts by approximately 1/4 turn.
7. Relieve drive belt. To do this, turn the tensioning lever of the tensioning roller clockwise with a socket wrench (a/f 15) and hold, remove the belt from the drive pulleys of the air-conditioning compressor, hydraulic pump and the generator.
Relieving and removing belt.
8. Unscrew the three already loosened fastening screws of the belt pulley and remove the belt pulley from the hydraulic pump.
9. Remove holder for oil filter bracket.
10. Remove generator. To do this, unscrew and remove the left generator fastening screw -A- (a/f 15) in the direction of travel. Subsequently remove the deflection roller (a/f 15) -B- under the generator. Unscrew the right generator fastening screw -C- (a/f 15) approximately 10mm and subsequently drive in the screw head with a hammer and aluminum mandrel until it is flush. This loosens the front threaded bushing in the generator swivel arm. Remove fastening screw. Remove generator from the bracket.
11. Turn generator and disconnect electrical connections. To do this, disconnect B+ wire and pull off the plug.
Note;
- The hydraulic pump can only be removed after removing the air-conditioning compressor.
12. Remove hydraulic pump. To do this, undo the fastening screws (M8) of the expansion tank -(upper two arrows)- and loosen the four screws -lower arrows- (three M8 screws and one M6 screw) on the hydraulic pump.
13. Remove temperature sensor for engine-compartment fan.
14. Loosen three hexagon-head bolts on the air-conditioning compressor.
15. Remove air-conditioning compressor with the connected lines towards the rear and disconnect the electrical plug connection at the same time. Place the air-conditioning compressor onto a padded surface.
16. Remove the hydraulic pump with the connected lines and set aside.
17. Drain coolant. In order to reduce the excess pressure in the cooling system, carefully open the closure cap of the coolant expansion tank. Undo coolant drain plugs on the left and right and collect coolant in a suitable container, so that it can be re-used. Then equip the drain plugs with new sealing rings and tighten to a torque of 10 Nm (7.5 ft. lbs.) to 15 Nm (11.0 ft. lbs.).
18. Pull off right and left coolant hose from the necks. Remove the locking clip in the direction of the arrow for this purpose.
19. Check or renew the locking clip if necessary. Remount the locking clip onto the coolant necks. The locking clips on the right coolant hose must not be confused.
20. Remove coolant flange on the right cylinder head (cylinder 4-6). Remove the holding clamp on the coolant pipe. Loosen two hexagon-head bolts. Remove holder and coolant flange.
21. Loosen hose clamp -arrow- on the coolant hose and pull coolant hose off the bracket.
22. Undo generator bracket. Loosen the four fastening screws -arrows- and pull the generator bracket to the right and remove.
23. Undo hose clamps on the coolant hoses. To do this, open the hose clamps -arrow-.
Warning:
Danger of injury!
Wear protective gloves!
24. Cut coolant hoses, e.g. with a knife, at the positions shown -arrows-. Pull off the hose residues.
25. Remove coolant flange on the left cylinder head (cylinder 1-3). Pull the electrical plug connection off the temperature sensor and open the spring band clamp.
26. Loosen two hexagon-head bolts (M6) and remove flange from the left cylinder head.
27. Undo coolant hose from the oil cooler bracket and pull off.
28. Undo coolant hose -A- and coolant hose -B- and pull off. Remove and dispose of sealing ring -C-.
29. Remove coolant hose between coolant expansion tank and coolant pump.
30. Remove coolant hose from the coolant pump.
31. Remove coolant residue from the housing ribbing, e.g. absorb with cloth.
Installing coolant hoses
1. Fasten right coolant hose to the oil cooler bracket.
2. Mount the coolant line in the area of the cylinder bank 4-6.
3. Fasten coolant hose -A- and coolant hose -B- to the cylinder bank 1-3 between the oil cooler bracket and coolant guide housing. Insert new sealing ring -C-.
4. Mount the left coolant flange to cylinder bank 1-3.
5. Mount the spring band clamp and electrical connection plug to the coolant temperature sensor.
Warning!
Swapped locking clips on the right coolant hose lead to coolant loss and consequently to engine damage.
In order to prevent the locking clips from being swapped, refit the engine-side locking clip immediately after removing the coolant hose.
6. Two different locking clips are fitted on the right coolant hose. The locking clips must not be confused.
- Distinguishing characteristic: Locking clip -inset A for fixing the right coolant hose on the coolant pipe (body side), Part No.: 996.106.802.11; dimension X: = 23 mm.
- Locking clip -inset B- for fixing the right coolant hose (engine side), Part No.: 996.106.802.10; dimension x: = 31 mm.
7. Check whether locking clips are properly seated.
8. Fit coolant hoses on the left and right. Coat the sealing rings and seal area liberally with water.
Part No. of left coolant hose: 99610650274
Part No. of right coolant hose: 99610650174
9. Push on coolant hose. To do this, align the flange of the coolant hose as shown (lug/groove). The coolant hose must engage audibly. Then check whether it is fitted properly by tilting it on both sides and by pulling on it.
10. Coat the coolant hose with water and fasten to the flange of the coolant pump. Engage coolant hose to the upper holder.
11. Coat the coolant hose with water and fasten to the flange for the coolant expansion tank. Observe the installation position of the hose clamp or spring band clamp.
12. Fit coolant hoses over the coolant pump. Use water for easier mounting. Observe the position of the hoses. The markings on the coolant hoses must be aligned with the lugs of the bracket. The part numbers must be legible from the right.
13. Fasten hose clamps. Observe the correct position. Fasten the hose clamps twisted slightly downwards.
Note;
- If incorrectly positioned, the generator bracket can make contact. This could lead to leaks.
14. Install generator bracket. Equip the connection fitting with new sealing rings (2 ea.) and attach the generator bracket to the coolant neck (cylinder bank 1-3).
Note;
- Insert the front right hexagon-head bolt -inset- with Loctite 574.
15. Fasten generator bracket.
Tightening torque: 65 Nm (48 ft. lbs.)
16. Mount right coolant flange to the cylinder bank 4 - 6. To do this, equip the connection fitting with new sealing rings (2 ea.) and insert new sealing ring on the cylinder head.
17. Fasten two hexagon-head screws and holder to the coolant flange.
18. Fix the coolant pipe with holding clamp.
19. Insert hydraulic pump into the bracket but do not fasten yet.
20. Mount air-conditioning compressor; insert spacer sleeve for this purpose or fasten the spacer sleeve to the hexagon-head bolt with grease.
21. Fasten the spacer sleeve with grease.
22. Join the electrical connections before the final installation position. Insert the air-conditioning compressor and fasten.
Tightening torque: 23 Nm (17 ft. lbs.)
23. Fasten hydraulic pump.
24. Additionally fasten the temperature sensor for the engine compartment fan to the right expansion tank fastening screw.
25. Install generator. Fasten B+ wire to the generator. Make sure that the mounting position is correct in the upper cable guide. Push plug connection on the generator and press in. The plug must engage audibly. Put the generator into the bracket.
Tightening torque: 15 Nm (11.0 ft. lbs.)
26. Position the right fastening screw -C-. Position the left generator fastening screw -A- in the direction of travel. Install deflection roller -B- under the generator and tighten. Tighten the right and left fastening screws of the generator.
Tightening torque for all three screws: 46 Nm (34 ft. lbs.)
27. Mount the belt pulley of the hydraulic pump with the fitted drive belt of the hydraulic pump. Screw in three hexagon-head bolts by hand.
Note;
- The hexagon-head screws can be fastened after tensioning the drive belt.
28. Fit drive belt. To do this, turn the tensioning lever of the tensioning roller clockwise and hold. At the same time, place the drive belt onto the drive pulleys of the air-conditioning compressor, the idler pulley and the generator. Now slowly release the tensioning lever.
29. Place the drive belt onto the idler pulley.
Complete view of fitted drive belt.
30. Fasten the belt pulley of the hydraulic pump after tensioning the drive belt.
Tightening torque: 23 Nm (17 ft. lbs.)
Note;
- Check that the installation position of the drive belt on all drive pulleys is correct. Raise vehicle and check the lower drive wheels. Always use a light source to do this (e.g. mini electric torch).
31. Fit air cleaner assembly.
32. Bleed the cooling system.
Refer to Draining and filling in coolant (includes: bleeding the cooling system).
33. Enter radio code.
34. Perform a test drive.
Tightening torques