Coolant Reservoir Replacement

[questforbalance]

I have a 2002 C4S. The coolant reservoir is leaking and I tried to replace it. I spent two days trying to get it out. I lowered the engine by removing the engine mounts and the existing reservoir could be moved around but could not be taken out. It seems that there is a large metal coolant tube on the bulkhead under the coolant reservoir that just would not let the coolant tank come it. I lowered the engine as much as it would go without removing the structural supports under the car. Has anyone taken the coolant reservoir out of the C4S? The tank is huge and thus not the usual tank. I got it to move around almost freely, but could not get the additional 1/4 I need to get the darn thing out. I would appreciate some experienced advice.

Thanks in advance.

[Ahsai]

Have you removed the black plastic bracket that the tank mounts to? That worked for me ('03 C2 so it might be different). Other ways I heard are to disconnect that big coolant pipe you mentioned or to try to push the engine to the right. I would think that also means the engine cannot rest on the cross member.

[questforbalance]

Oh wow, That is a great idea. How do I remove that black plastic bracket. I was looking for the fastening mechanism but could not see it. I wopuld rather remove that black plastic bracket instead of the coolant pipe.

[Ahsai]

The black bracket is not easy either. You have to slide the tank off the bracket first, then you will see (with an inspection mirror) two up side down screws holding the bracket to the body frame. The tank will be blocking the screws but with patience you should be able to remove them. Reinstall is the reverse but some people were only able to put back one screw, which seems to be enough to hold the tank. With patience, I managed to reinstall both screws.

[Dharn55]

If you have a C4 did you take the fuel filter off the mounting bracket on the tank. My car is a 2000, so the tank is a little different (and almost twice the cost) but I had mine out this weekend. I took out the air box, the air pump and moved a lot of hoses. It was still a ***** to get out. There was no way it would come out without the fuel filter taken off and the engine lowered. Then it was still difficult to get it out. Just kept wiggling it and checking clearances. Same thing getting it back in.

I had a few drops leaking onto the exhaust, thought the tank was leaking. It was replaced once when the car was 2-3 years old under warranty. Once I got it out I pressue tested it as the old style tank lists for $375! The tank did not leak, held 20+ lbs. it was the cap that was leaking. It released pressure over about 20-25 lbs. but hen did not reveal, so it slowly leaked. The cap had been replaced once before. Go everything back together this afternoon and took it for a long drive, no more leak!