Coolant Line/Hose: Service and Repair
WM 196120 Removing and installing coolant pipes (with heater pipes) (includes repair solution)
Preliminary work
Preliminary work
Information:
The engine does not need to be removed in order to remove the large coolant pipe at the bottom.
The large one-piece coolant pipe (at the bottom) will be damaged irreparably during removal and is replaced by a multi-piece coolant pipe comprising a pipe, connection piece, two clips and a hose.
If the old plastic coolant pipes (heater pipes and lower coolant pipe) are leaking, all pipes must always be replaced (not just the sealing rings).
When removing the old plastic coolant pipes, replace them with the metal coolant pipes.
1. Drain coolant.
2. Disconnect the battery.
3. Remove intake-air distributor. Removal and Replacement
4. Close off intake openings to prevent dirt or small parts from falling in.
Information
Component overview
Component overview of upper coolant pipes (heater pipes)
Upper metal coolant pipes (heater pipes)
1 - Thermostat housing
2 - Screw
3 - Sealing ring
4 - Heater pipes
5 - Two-part holder (top part and bottom part)
6 - Screw
7 - Sleeve
8 - Sealing ring
Component overview of lower coolant pipe
Lower metal coolant pipe (assembly)
1 - Temperature sensor
2 - Screw plug
3 - Sealing ring
4 - Cable holder (clip)
5 - Seal
6 - Sealing rings
7 - Lower coolant pipe
8 - Clip
9 - Coolant hose
10 - Coolant connection piece
Removing coolant pipes
Removing upper coolant pipes (heater pipes)
1. Open both cable holders and press wire harness to one side -arrows-.
Cable holders for engine wire harness
2. Unclip vent line and remove three screws -arrows-.
Loosening holder
3. Remove holder for the three coolant pipes. To do this, remove the top part of the plastic holder by releasing the locking lugs (press them together) and pull it up and off -arrows-.
Mount for coolant pipes
4. Loosen connected coolant hoses on the upper coolant pipes and pull them off.
5. Remove housing cover on coolant regulator. Remove housing cover with the attached heater pipes. The thermostat insert remains fitted.
6. Set down housing cover for coolant regulator with the attached heater pipes.
7. Pull the coolant pipes -4- out of the housing cover -1-.
Heater pipes
Removing lower coolant pipe
Caution:
Danger of injury if the saw slips!
- Wear protective gloves.
- Work carefully.
1. Remove heater pipes. See above.
2. Cut plastic coolant pipe close to the coolant guide using a metal saw blade. A pneumatic or electric body saw can be used if necessary.
Sawing coolant pipe
3. Turn the coolant pipe up. Use a suitable pliers if necessary.
Turning the coolant pipe
View of engine with coolant pipe removed
4. Remove both parts of the coolant pipe by turning them. Use a suitable pliers if necessary. Clean the bore fittings in the crankcase and in the coolant guide. Use a cloth to absorb all remaining coolant.
Installing coolant pipes
Installing lower coolant pipe
Lower coolant pipe (assembly)
1 - Temperature sensor
2 - Screw plug
3 - Sealing ring
4 - Cable holder (clip)
5 - Seal
6 - Sealing rings
7 - Lower coolant pipe
8 - Clip
9 - Coolant hose
10 - Coolant connection piece
1. The metal pipe, connection piece, two clips, sealing rings and the coolant hose are required for carrying out repairs. Check the sealing rings and make sure they are fitted correctly. Never twist sealing rings during installation.
Lower coolant pipe (multi-part)
Information:
000 043 204 68 (Status 02/07) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease that can be used for connection pieces and sealing rings in oily or water-carrying areas.
Use "Kluber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks.
"Kluberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.
2. Coat the sealing rings and the inside of the coolant hose lightly with the recommended grease.
3. Press the connection piece with the sealing rings as far as it will go into the rear coolant guide.
Pressing in connection piece
4. Slide both clips and the piece of hose onto the coolant pipe. Push on the screw-type clamps in an offset position. Slide piece of hose on fully so that it does not project out. Insert coolant pipe with the greased sealing rings into the crankcase.
Fitting coolant pipe with hose and clips
5. Turn the coolant pipe towards the connection piece and slide the coolant hose onto the connection piece. When removing it later, the coolant hose should be cut open and replaced if it is seated very securely.
Hose in position
6. Press all components into the correct position and move the clips so that they can be fitted without colliding. Move clip locks into an offset installation position -8- and tighten them.
Clips in position
Lower coolant pipe (assembly)
Installing upper coolant pipes (heater pipes)
Information:
000 043 204 68 (Status 02/07) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease that can be used for connection pieces and sealing rings in oily or water-carrying areas.
Use "Kluber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks.
"Kluberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.
1. Apply a thin coat of grease on the sealing rings on the coolant pipes -3- and -8-. Carefully press the coolant pipes -4- into the thermostat housing cover -1-.
Upper coolant pipes (heater pipes)
1 - Thermostat housing cover
2 - Screw
3 - Sealing ring
4 - Heater pipes
5 - Two-part holder (top part and bottom part)
6 - Screw
7 - Sleeve
8 - Sealing ring
2. Fit thermostat housing cover with the attached heater pipes.
3. Fit coolant hoses for the upper coolant pipes. Secure clips.
4. Fit holder for the coolant pipes.
5. Screw in three fastening screws -arrows-. Clip in vent line. - Tightening torque: 10 Nm (7.5 ftlb.)
Securing holder
6. Fit engine wire harness on coolant pipe holders -arrows-.
Cable holders for engine wire harness
Subsequent work
Subsequent work
1. Fit intake-air distributor.
2. Fill in coolant and bleed the system.