Work Procedure

Retrofitting the two left studs on the engine carrier with caps, checking the distance and condition of the coolant hose (supply) and replacing the coolant hose - depending on the result of the check.

1. Lift vehicle with platform lift according to instructions in --> Workshop Manual "401000 Lifting the vehicle".

2. Remove rear underbody cover according to --> Workshop Manual "519419 Removing and installing rear cover - section on "Removing"".

WARNING
Burns caused by touching hot coolant lines and hoses.

^ Coolant lines and hoses can be very hot.

--> Do not begin work until the engine has cooled down.

--> Wear protective gear if necessary.





3. Check coolant hose (--> Figure 1 -Item A-) close to the two left studs for the engine carrier (--> figure 1-Arrows-) for damage (visible pressure points or chafing damage).





4. Retrofit the two left studs for the engine carrier (--> Figure 2-Item A-) by placing a cap, Part No. 000.043.206.69 (--> Figure 2-Item B-) on each one.

Note
Only perform check when coolant is cold (ambient temperature) and cooling system is depressurized.

5. Check coolant nose (supply).

5.1 Open and take off cap on coolant tank.





5.2 Check coolant hose for damage close to the studs (--> Figure 3-Arrows-) by examining it carefully.

- If the coolant hose is damaged close to the studs, replace the coolant hose - continue with Step 6.

- If the coolant hose is not damaged, continue with Step 5.3.

5.3 Check distance between the coolant hose and the caps fitted on the studs.

Note
The two 2.5 mm feeler gauges together give the set point dimension of 5 mm.





5.3.1 using both feeler gauges (setpoint dimension of 5 mm), check the distance (--> figure 4-Item A-) between the coolant hose and the caps fitted on the studs.

Check whether both feeler gauges (setpoint dimension of 5 mm) can be inserted between the coolant hose and studs (--> figure 4-Item A-) without deforming the coolant hose or changing its position.

- The feeler gauges cannot be inserted at one of the two studs, the distance is less than 5 mm - continue with Step 6, replace coolant hose.

- The feeler gauges can be inserted at both studs, the distance is greater than or equal to 5 mm - continue with Step 7.

6. Replace coolant hose.

6.1 Remove center underbody cover according to --> Workshop Manual "519319 Removing and installing centre cover - section on "Removing"".

6.2 Drain coolant according to --> Workshop Manual "193817 Draining and filling in coolant-section on "Draining".

Note
Contrary to the description in the Workshop Manual, do not secure the coolant hose to be replaced (supply) on the coolant line after draining the coolant.





6.3 Disconnect coolant hose (supply) at the Henn coupling connecting it to the engine. To do this, use a screwdriver to release the spring clamp (--> Figure 5-Item A-) and pull the coolant hose off the Henn coupling (--> Figure 5-Arrow-).

Then clip in the spring clamp at its original position.

6.4 Dispose of coolant hose.

6.5 Fit new cooant hose, Part No. 987.106.501.06. Push the coolant hose into the Henn coupling on the coolant line and into the Henn coupling for the engine until it engages audibly.

Check that the coolant hose is fitted securely by pulling on it.

6.6 Install center underbody cover according to --> Workshop Manual "519379 Removing and installing centre cover - section on Installing"".

6.7 Fill with coolant according to --> Workshop Manual "193817 Draining and filling in coolant - section on "Filling in"."

7. Install rear underbody cover according to --> Workshop Manual "519419 Removing and installing rear cover - section on Installing"".

8. Lower the platform lift.

9. Close cap on coolant tank.

10. Enter the Workshop Campaign in the Warranty and Maintenance booklet.