HELP - '01 Coolant Reservoir Removal

HELP - '01 Coolant Reservoir Removal and subsequent replacement!!!!!!!!!!!!!!!!! I am way past the point of no return on this. I've disconnected the sensor switch, the 3 coolant hoses, the 3 fuel lines connections, pushed the fuel filter to the rear and have dropped the CR out of its rails. However, I can't get the thing out of there!!!!!!!!! Has anyone with an '01 done this themselves? Do I have to drop the engine and does that move it out of DIY land? Any and all thoughts would be appreciated. Oh, it's a '01 C4 Cab. TIA Jeff I usually don't double post but I will be posting this to renntech too so excuse me if you see it there too.

Sorry I can't help, but I have read somewhere that it CAN be done with the engine as it is. I'm sure someone will jump in with instructions. Good Luck!

Did you move the air pump out of the way? and the two fuel lines? Then move the tank towards the engine?

Yes. The airpump has been removed and all (I believe) hoses and lines are disconnected or removed (which will bring me to a question later about how to route the fuel line when I reinstalled it ) It just doesnt seem to be able to make the turn even though it is loose in the cavity. Thanks, Jeff

don't be afraid to yank and shimmy that thing out of there...i did mine about 4 months ago. i disconnected everything you have and slowly worked the tank twisting this way and that until it finally came out.

Try rotating the tank counter-clockwise 90 degrees while lifting the side closest to you up and tilting it towards the front of the car.

Thanks guys but there just doesnt seem to be enough clearance between the mounting rails for the CR itself, the fuel rail and the bump in the sheet metal for the rear light housing. Is it that big of a deal to drop the engine 1/2"? or even a few inches? Oh and to just add to the drama...I tried putting the CR back into position as I was considering putting it all back to together and limping over to my indy and I can't even get that done! Jeff

put a floor jack under the engine, completely remove the 2 19mm bolts from the bottom that go into the engine plate lower the engine down till it rests on the cross memember. you will now have lots of room and it will come right out

Ah now we're talking...can you give more specifics on the location of those 199mm bolts???? Thx, Jeff

lay on your back and look up theres one on each side follow the plate that the cats are bolted to outwards you will need a long extenstion (8 inchs or so and a deep well socket 19mm) i hope you have air tools cuz thats gonna suck with a ratchet

Thanks that helped a lot...unfortunately, my mufflers are getting hung up on the heat shields and body before the point that I can get the CR out but I am sooo close now. Just a little frustrated. oh and for the record, I had no trouble with those bolts with just a rachet so I guess I got lucky. Thanks, Jeff

Update: I've removed my mufflers but that is still not giving me enough room. This is really frustrating...Should I break the CR to get it ot of there? And, if I do what does that say about my chances of getting the new one in there? Help! Jeff Is there anybody near me (Syosset, LI) that wants to stop by and gawk on this rainy Saturday?

u shouldnt need to take the mufflers off, lowering the engine should have given you plenty of room what is it hitting on, you dont have the lower coolant hose hook up stuck on the harness do u ? can u tajke a picture ?

Thanks for the response. What I think is the lower coolant hose (the one that is metal under the CR) is out of the harness and tucked down between the body and the engine. The hang up is one of the hose connectors (on the tank) and the fuel rail and/or the CR tank itself and the body of the car where the lights are...pictures to follow.... Jeff Pics:

Jeff it can be done. I know your frustration. I have done it myself on my 01. It takes some rotating and manuavering. To makae things easy on you, cut the last part of the hanger tab closes to the sheet metal as shown in you second form the top picture. You can use a hack saw blade. This will give you extra clearance to get the thing out. Then by rotating and pulling it comes out rather easily. I marked where to cut. The plastic is tough (you will wonder how the stupid thing cracks) and it will take you a few minutes. If you have dremil with a flexible cutting shaft you can make quick work of it. I tried to mark on your picture the part to cut off. Cut from the top of the hanger (about where my line is) at an angle to top of the tank. You just need to get the corner of hanger off but it makes it a little easier to cut if you cut into the tabs. PUtting the new one in is a easy (you don't have to cut the tab).

your bound up, you will need to put it back in and under the hanger then just wiggle it out, ive done 100 of them some of them fall out some of them take 3 hours to pull out sometimes a screw driver stuck in the lower fitting on the cr can help you bend it away from the rail so you can yank it out

Thanks you both for your replies....I am going to try a combo of these suggestions. Be right back... Jeff

Got the bastard out of there. The screw driver in the lower fitting was the ticket. It gave me the extra leverage that I needed. Unfortunately, I had one casualty...the lower cooling hose harness got nuked so I need to order one of those before I jam the new CR tank back in there. I must say, now that I see the crack in the tank I have to wonder about this being either a design flaw or a manufacturing error and I can only assume that every 996 will experience this at some point. Thanks for all your help and I will get back to this thread on the return trip later in the week. Jeff

i usually throw them on the ground and swear at it once it comes out

Then at least I got that part right on the first shot

Just to finish the story... It took me a while to find the part number of the clip that I crushed during the removal process and also most as long to get the new part but I finally did get it. However, while not nearly as difficult as it was to remove it, the new CR was something of a bitch to get back in and required the lowering of the engine (simple), removal of one of the motor mounts (simple) and some dremel work on the front edge of the upper CR bracket (again simple). Thank you for those that helped me...without your support I would have punted and would not have ended up knowing nearly as much as I do now about my car. BTW, YES, I would do it again and would suggest that other do it themselves if they have some DIY skills. Jeff

Well, I'm going to try replacing the CR my 01 C2 Cab on Sunday in lieu of the dealer's quote of 6 hours labor and a complete drain, flush refill of the cooling system. I figured they were going to hit me for close to a grand. We'll soon see whether it was the right decision to DIY it. Your Post was a GREAT help to prepare me for what I may be in for. Thanks!

Good luck. Use patience and just take your time. If you get stuck post pics here and I'm sure there will be someone here to help. Jeff