Coolant Reservoir: Service and Repair

Removing and installing coolant expansion tank

Removal





1. Unscrew the fastening screw M6 x 34 (a/f 13) on the rear side of the air cleaner housing.
2. Disconnect the hot film mass air flow meter line of the air cleaner housing:
^ Pull off electrical wire connector of the hot film mass air flow meter.
^ Open omega clip.
^ Remove electrical wire.





3. Tilt the air cleaner housing upwards to the right by 90° and then turn the air cleaner housing and remove from the engine compartment.





4. Unscrew the hose clamp (a/f 7) between the air cleaner housing and the cowl.

Note:
^ In order to avoid any damage when removing the intake pipes, pull off the connector.

5. Pull off the electrical connector on the solenoid hydraulic valve of the cylinder bank 1-3.
6. Undo pressure pipe -middle- by removing the spring clip -5- , hose clamp -3- , hexagon-head bolts -1 & 2- and electrical plug -4-.
7. Pull off vacuum hose to the control valve.





8. Unscrew fuel return line -1- and fuel supply line -2-. It is important to counter when performing this step.
9. Remove fuel filter.





10. Completely remove fuel filter with holder. To this, bend the retaining clip upward as shown -arrow and at the same time remove the filter with holder.





11. Remove holder for fuel return line on the intake pipe (hexagon-head bolt M 6).





12. Undo three fastening screws on the front intake distributor separation point.





13. Remove hose clamp and pull off ventilation hose from the intake pipe.





14. Unscrew upper hexagon-head bolt, lift intake pipe out of the shaft bolt and remove rearwards. Remove and dispose of seal.
15. Disconnect coolant hose with commercially available hose clip.





16. Unscrew spring band clamp or hose clamp on the coolant expansion tank.
17. Prepare auxiliary hose (internal diameter ) and a length of approximately. 1 meter.
18. Pull off disconnected coolant hose, push auxiliary hose onto the supports and collect coolant in a container.





19. Disconnect electrical plug connection from the sensor for the coolant-level indicator.





20. Undo the hexagon nut.





21. Pull coolant expansion tank out of the guide rails and remove rearwards.

Installation





1. Push coolant expansion tank into the guide rails and fasten.
2. Attach connector from the sensor for the coolant-level indicator.





3. Fasten the coolant hose with a new hose clamp 999.512.552.00. Observe the installation position of the screw-type hose clamp. The screw must be installed pointing vertically downwards.
4. Install intake pipe:
^ Fix new seal onto the separation point/intake distributor.
^ Place suction line on the shaft bolts, at the same time push the hose of the recirculating air valves onto the suction line.
^ Fasten the hexagon-head bolt.





^ Fasten ventilation line from the oil tank onto the intake distributor.





^ Fasten separation point.
5. Position the fuel filter with holder on the coolant expansion tank and press it down at the rear. The holder must engage audibly.
6. Install fuel hoses.
7. Install rear pressure pipe.
8. Fit air cleaner assembly.
9. Remove hose clamp.
10. Fill in coolant.
11. Warm engine up to operating temperature. Perform tightness test.