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G500 Auxiliary coolant pump hoses
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Posted 11/28/2019 11:25 PM
G4Garret
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Date registered: Apr 2006
Location: Oak Ridge - Knoxville - Windrock Tennessee
Vehicle(s): 2000 G500, U1100, SLK350, LR 101, WC-63 6x6
Posts: 243
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G500 Auxiliary coolant pump hoses

Can someone recommend a source for those smaller hoses that go to the little electric auxiliary pump? Specifically the one from the main water pump to the auxiliary pump?

The usual online websites never show these for the G500.


For the story, I had my fist power train failure on my G500. Apparently the viscous fan clutch seized up, sort of crookedly, causing it go go out of balance and ruin the water pump while I was cruising at 75 mph on the interstate, which resulted in a water pump replacement operation somewhere in Arkansas in an empty truck stop lot, in the middle of the night, the rain, the cold, with a head cold, on the tail end of a 3,000 mile trip.

Even though I've never worked on the M113 other than changing spark plugs, I managed to successfully replace the pump, fan coupling, idler pulley, tensioner pulley, and belt (after 9 hours), and in the process have come to the conclusion that I need to get with things and do some proper Preventive Maintenance (PM) on this vehicle. I figure after 250,000+ miles, it's time to start paying attention to these things, especially since I absolutely love this truck and don't want to ever give it up.

I have to admit, I never imagined this truck would be so reliable, mechanically. Other than brake pads, shock absorbers and one tie-rod end, this truck is now 20 years old, 250,000 miles, and and this was the first significant mechanical failure. Of course almost everything electrical has broken at least once... But I digress, I need to figure out what PM to do.

What is the collective though on high-mileage PM? So far, I'm thinking:

1. Replace all hoses on the engine

2. Replace some gaskets that are known to eventually leak (even though they are not)

3. Do some kind of service on the front axle that I keep reading about here and there

4. Change all fluids and lube everything

5. Whatever maintenance is in the workshop manual that I keep ignoring.

6. What else?


Garret



Edited by G4Garret 11/28/2019 11:29 PM
#241267
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Posted 11/29/2019 6:48 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: G500 Auxiliary coolant pump hoses

Those hoses should be listed on the EPC. However, I have found that some are NLA. The most common one to fail - runs back off the top of the engine - is certainly NLA. I haven't checked lately, but I wouldn't be surprised if there are others..
#241268 - in reply to #241267
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Posted 11/29/2019 9:00 AM
vancouverChris
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Date registered: Feb 2019
Location: Vancouver
Vehicle(s): 2003 G500
Posts: 15

RE: G500 Auxiliary coolant pump hoses

G4Garret well done on the truck stop repair! that sounds like my nightmare. You must carry a plethora of tools, what do you generally carry? Im trying to build a tool set for my truck. Just so I know what to do in the future, how did you go about getting all the parts to you?
#241269 - in reply to #241267
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Posted 11/29/2019 11:41 AM
G4Garret
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Date registered: Apr 2006
Location: Oak Ridge - Knoxville - Windrock Tennessee
Vehicle(s): 2000 G500, U1100, SLK350, LR 101, WC-63 6x6
Posts: 243
100
RE: G500 Auxiliary coolant pump hoses

Chris, thank you for the compliment.

I definitely had some lessons learned. Regarding the parts, I had them with me. Back many years ago, when the truck hit about 150,000 miles, I went ahead and purchased a water pump (which wasn't exactly the right one) and viscous coupling, along with tensioner, idler pulley, and serpentine belt, mainly because I'd read those latter few parts commonly failed. I packed them into an re-used ammo can, along with a few other spare parts. So, I was in pretty good shape for parts, but I did learn I needed some additional supplies. I had planned to go ahead and proactively install these, once I got all of the hoses - which I never got, because no one had the small aux coolant pump hoses.

By far, this was the most difficult water pump replacement that I've ever done on a passenger vehicle, and having never worked on the M113, I wasn't giving myself very good odds, but I figured, here I am far away from any dealer, or any garage that would be open, and no matter what, I'd be stuck for a day, so why not just give it a try. I know you didn't exactly ask, but a few things that helped:

1. Good lights. I had a headlamp and a couple of small LED flood lights, and a good small penlight
2. A good heavy coat in order to stay warm.
3. A roll of paper towels
4. A towel to protect the fenders
5. 10 sets of surgical gloves

For tools, I keep basic hand tools with me, and I had augmented this with a set of deep-well 3/8 in. external Torx sockets, 3/8 in. internal Torx sockets, and 3/8 in. Allen head sockets, since I noticed the M113 is covered with this style (torx) of bolt head. I'm not sure that's the proper name though. Also, it might be a good idea to get 1/2 inch drive sockets for the larger bolts.

1. Basic screw drivers in a couple of sizes, positive and negative styles
2. Two sized of Channel Lock pliers
3. Slip joint pliers
4. pair of 5 inch hemostats
5. 1/2 inch socket set with both standard depth and deep well sockets
6. 1/2 inch breaker bar (you'll need this if you ever break a shock in the wild)
7. 3/8 inch socket set with both standard depth and deep well sockets (see comment below)
8. 3/8 inch breaker bar
9. 3/8 inch deep well external Torx socket set
10. 3/8 inch internal Torx sockets,
11. 3/8 inch Allen head sockets,
12. Combination wrench set
13. Small hammer ( strangely, I never used this)
14. 8 inch cable ties
15. Duct tape (as if I need to even say this)
16. 5 minute epoxy


Now, what I didn't have, and needed:

1. Special tool to hold the water pump pulley while loosening the viscous clutch
2. Special wrench for the viscous clutch (a thin large wrench - I don't know what size)
3. Blue Locktite
4. General purpose grease (this is needed to hold the thin rubber gasket in place before bolting on the water pump)
5. Antifreeze

So what I did for the special tools, I noticed there was a truck stop not too far away, so I hiked to it and they had a largish oil filter wrench. I got that oil filter wrench, a couple gallons of anti-freeze, some cold-medicine, a subway sandwich, and then hiked back through the mud.

I used the oil filter wrench, jaws wrapped with duct tape, to grasp the water pump pulley, and a pair of large channel lock pliers on the viscous clutch to break it loose. This was essential to get loose, and I think I was pretty lucky, as the oil filter wrench just barely was able to hold the pulley. This is where you really need the special tools.

I went very slow, took a lot of pictures, took a lot of breaks, and managed to get it all done in about 10 hours, counting breaks. I also broke the temp sensor on the front of the motor, but was able to rig it with a cable-tie, epoxy and duct tape. Also, it's best to just go ahead and remove everything that is in the way, sensors etc.

I did have trouble with the new water pump. It didn't have the outlet for the oil cooler. So, I just had to block it off by cutting the little coolant hose from the oil cooler slightly short, stuffed a 5/8 inch bolt into it, and clamped it with the hose clamp. Of course this means that I get to do all of this all over again when I get the right water pump. So, a word of warning, make sure you get the right water pump, as apparently some G500's must not have the oil cooler. See photo.

That's my story.

Garret

EDIT: I need to add a big THANK YOU to a man in a van at the truck stop who gave me a 3/8 in. breaker bar. Somehow mine was missing from my tool kit, and this was about essential to removing the zillion bolts that hold the water pump on. He overheard me asking the truck stop cashier if they had any more tools, and he just took it right out of his tool box and gave it to me. I paid him for it, and he very reluctantly took $20. He said it was just an old tool, but it was a quality tool (older S-K).








Edited by G4Garret 11/29/2019 3:18 PM




(20191123_192502 smaller.jpg)



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(20191123_160832 smaller.jpg)



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Attachments 20191123_192502 smaller.jpg (158KB - 0 downloads)
Attachments 20191123_192506 smaller.jpg (154KB - 0 downloads)
Attachments 20191123_192508 smaller.jpg (140KB - 0 downloads)
Attachments 20191123_160832 smaller.jpg (148KB - 0 downloads)
#241270 - in reply to #241269
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Posted 11/29/2019 1:45 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: G500 Auxiliary coolant pump hoses

I think the two small hoses around the recirculation pump are #'s 188 & 200 in the attached diagram.

Edit: The diagram is too large to post as an attachment here. The part numbers are:

A.463.501.66.82
A.463.502.77.82
#241272 - in reply to #241267
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Posted 11/29/2019 2:34 PM
G4Garret
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Date registered: Apr 2006
Location: Oak Ridge - Knoxville - Windrock Tennessee
Vehicle(s): 2000 G500, U1100, SLK350, LR 101, WC-63 6x6
Posts: 243
100
RE: G500 Auxiliary coolant pump hoses

Thank you Dutch! I can get serious now.

Garret
#241273 - in reply to #241272
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Posted 11/29/2019 7:43 PM
paulunm
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Date registered: Jan 2015
Location: Los Angeles
Vehicle(s): 2000 G500
Posts: 124
100
RE: G500 Auxiliary coolant pump hoses

DUTCH - 11/29/2019 10:45 AM

I think the two small hoses around the recirculation pump are #'s 188 & 200 in the attached diagram.

Edit: The diagram is too large to post as an attachment here. The part numbers are:

A.463.501.66.82
A.463.502.77.82


Dutch, can you resize the diagram, or email it to me? I'm not familiar with the recirculation pump (Webasto I don't have?)- I like to proactively replace hoses, I've done the upper and lower rad hoses.
#241275 - in reply to #241272
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Posted 11/29/2019 7:50 PM
G4Garret
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Date registered: Apr 2006
Location: Oak Ridge - Knoxville - Windrock Tennessee
Vehicle(s): 2000 G500, U1100, SLK350, LR 101, WC-63 6x6
Posts: 243
100
RE: G500 Auxiliary coolant pump hoses

I tried to shrink and convert it. It did not come out very well.
Garret


Edited by G4Garret 11/29/2019 7:58 PM




(MY 2000 G500 cooling system diagram.jpg)



Attachments
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Attachments MY 2000 G500 cooling system diagram.jpg (82KB - 2 downloads)
#241277 - in reply to #241267
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Posted 11/30/2019 1:37 AM
vancouverChris
Member


Date registered: Feb 2019
Location: Vancouver
Vehicle(s): 2003 G500
Posts: 15

RE: G500 Auxiliary coolant pump hoses

Garret, thanks for all the info! I hate to say but if I were in your position, my truck would have been on the back of a tow truck... I don't carry any of the parts, but I do have most of the tools, minus the deep well torx and the hemostats.. I didn't know we're doing surgery here lol

I now have a good shopping list, I think I'll start to carry basic replacement parts with me. All I carry now is the crankshaft position sensor.

Thanks again for all the info!!
#241278 - in reply to #241270
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Posted 11/30/2019 6:47 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: G500 Auxiliary coolant pump hoses

paulunm - 11/29/2019 7:43 PM

Dutch, can you resize the diagram, or email it to me? I'm not familiar with the recirculation pump (Webasto I don't have?)-


The recirculation pump is a small electric pump in the cooling system. It is not relat3ed to the Webasto auxiliary heater. On my G500 it is mounted on the inner right front fender linerl It operates for a few minutes after the engine is shut down to prevent hot spots in the engine and to provide some additional heating inside the truck if wanted.

The diagram I sent to and Garret posted is for a pre-MBUSA G500.
#241280 - in reply to #241275
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Posted 11/30/2019 12:54 PM
G4Garret
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Date registered: Apr 2006
Location: Oak Ridge - Knoxville - Windrock Tennessee
Vehicle(s): 2000 G500, U1100, SLK350, LR 101, WC-63 6x6
Posts: 243
100
RE: G500 Auxiliary coolant pump hoses

Chris, it is surgery. Believe me! Hemostats are handy, but not essential. They helped with both picking up dropped fasteners as well as using with pieces of paper towel to clean out the groove for the water pump's thin rubber gasket, bolt holes, etc. Keeping in mind the gasket groove is only about 3 mm wide, and there are 18 bolt holes in that water pump. Yes, 18 bolts...

As far as carrying spares, I really don't carry many, and wouldn't have normally had the pump and pulleys except that I'd been planning to replace them for the past several years, ever since the truck hit about 150K miles (now about 250K). Other than that, I only carry a full suite of spare sensors, a fuel filter, and serpentine belt.

An interesting thing happened when the pump bearing went bad, the serpentine belt came off the water pump pulley slipping behind it and up against the motor, but it just kept working! The belt was turning the alternator, power steering, etc, but not the water pump. Apparently there is enough tolerance with the tensioner to keep it tensioned, even though it was completely off the pulley and running up against the front of the motor. Kind of bizarre.

As far as making the decision to work on it or wait and be towed, I just figured I didn't have much to lose. I had most of what I needed, and I was going to be stuck for at least a day, probably 2 if I had it towed to a garage, and I had a 1,200 lb load of equipment that I could not leave, plus, I really wanted to get home. I would also say that 39 years of Land-Rover ownership and many repairs in in austere environments factor in there somehow.

Garret
#241286 - in reply to #241278
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