Installing Unit Carrier (Coolant Distributor Housing)

Information

Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).

Replace two seals and two O-rings on the unit carrier. Replace one seal on the coolant connection piece.

Fig 1: Identifying Unit Carrier Seals
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Replace molded seal on the connecting tube -3- .

Fig 2: Identifying Thermostat Housing And Connecting Tube
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Install unit carrier (coolant distributor housing).
1. 1 - External Torx screws, M8 x 70
2. 3 - Coolant connection piece
3. 4 - External Torx screw, M8 x 50
4. 5 - External Torx screw, M8 x 50
5. 6 - Unit carrier
6. 7 - Thermostat housing
1. 3.1. Insert unit carrier -6- into the thermostat housing -7- .
2. 3.2. Screw in and tighten three external Torx screws (E12, M8 x 50) -4, 5- on the unit carrier.
  → Tightening torque: 33 Nm (24 ft. lb.)
3. 3.3. Connect cable plug on the coolant temperature sensor.
4. 3.4. Install coolant connection piece.
  1. 3.4.1. Fit coolant connection piece -3- and tighten M8 x 70 Torx screws -1- .
    → Tightening torque: 33 Nm (24 ft. lb.)
  2. 3.4.2. Fit and secure spring band clamp on coolant hose.
  3. 3.4.3. Fit coolant hose on coolant connection piece -3- and secure with spring clamps on the Henn couplings. Make sure that the Henn coupling locks with an audible click.
Fig 3: Identifying Coolant Distributor Housing Unit Carrier
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Install bracket for the coolant pump.
1. 4.1. Replace O-rings.
  Grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
2. 4.2. Fit bracket for coolant pump -1- .
  1. 4.2.1. Turn bracket for coolant pump -1- slightly and guide into position from the right.
  2. 4.2.2. Carefully press bracket for coolant pump into the mounting -1- .
  Fig 4: Installing Coolant Connection Piece
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3. 4.3. Secure bracket for coolant pump -1- .
  1. 1 - Bracket for coolant pump
  2. 3 - External Torx screw, M8 x 50
  3. 4 - External Torx screw, M8 x 50
  4. 5 - External Torx screw, M6 x 20
  5. 6 - External Torx screw, M8 x 25
  1. 4.3.1. Screw in and tighten external Torx screws -3, 4, 5 and 6- .
  2. 4.3.2. Tighten one external Torx screw (E10, M6 x 20) -5- .
    → Tightening torque: 13 Nm (9.5 ft. lb.)
  3. 4.3.3. Fit and tighten one external Torx screw (E12, M8 x 25) -6- .
    → Tightening torque: 33 Nm (24 ft. lb.) .
  4. 4.3.4. Tighten two external Torx screws (E12, M8 x 50) -3- and -4- .
    To tighten the external Torx screw -4-, the tensioner must be turned and locked.
    
    → Tightening torque: 33 Nm (24 ft. lb.) .
Fig 5: Identifying Coolant Pump Bracket
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Install thermostat housing lid.
1. 5.1. Secure thermostat housing lid -1- .
  1. 5.1.1. Fit and tighten one external Torx screw (E10, M6 x 50) at the bottom of the thermostat housing.
    → Tightening torque: 13 Nm (9.5 ft. lb.)
  2. 5.1.2. Fit thermostat housing lid -1- and screw in and tighten three external Torx screws (E10, M6 x 50) -3- .
    → Tightening torque: 13 Nm (9.5 ft. lb.)
  3. 5.1.3. Tighten one external Torx screw (E10, M6 x 40) -2- .
    → Tightening torque: 13 Nm (9.5 ft. lb.)
2. 5.2. Secure intake coolant pipe -5- .
  1. 5.2.1. Replace O-rings.
    Grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
  2. 5.2.2. Press intake coolant pipe -5- into the thermostat housing.
  3. 5.2.3. Fit and tighten two external Torx screws (E10, M6 x 12) -4- on the intake coolant pipe -5- .
    → Tightening torque: 13 Nm (9.5 ft. lb.)
3. 5.3. Connect coolant hose to the thermostat housing lid -1- and secure with a spring band clamp.
Fig 6: Identifying Intake Tube And Thermostat Housing
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Install water connection piece -3- .
1. 6.1. Fit water connection piece -3- .
2. 6.2. Screw in and tighten six external Torx screws (E10, M6 x 25) -1- on the bracket for the coolant pump -5- and crankcase.
  → Tightening torque: 13 Nm (9.5 ft. lb.)
3. 6.3. Secure the vacuum line at the water connection piece -3- .
  Screw in and tighten one external Torx screw (E10, M6 x 12) -2- .
  
  → Tightening torque: 13 Nm (9.5 ft. lb.)
Fig 7: Installing Water Connection Piece
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Install vibration damper -1- .
→ 137519 REMOVING AND INSTALLING VIBRATION DAMPER - section on "Installing".

Fig 8: Installing Vibration Damper
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Information

The threaded bolt on the bracket for the engine carrier must be bonded using Loctite 243 and can only be subjected to pressure after a hardening time of three hours.
Install engine carrier bracket.
1. 8.1. Fit the drive belt -1- on the vibration damper.
  
  Fig 9: Identifying Drive Belt
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2. 8.2. Fit the engine carrier bracket -3- .
3. 8.3. Apply Loctite to the threaded bolt (stud) M10 x 120.
4. 8.4. Screw in and tighten threaded bolt (stud) M10 x 120.
  Screw two nuts -1- onto the M10 x 120 threaded bolt -2- to lock it and tighten the threaded bolt -2- .
  
  → Tightening torque: 5 Nm (3.5 ft. lb.)
  
  Fig 10: Identifying Engine Carrier Bracket Threaded Bolt (Stud)
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