(1995 D1 with a 300TDi)
200 miles into a 500 mile day, I pull into a rest area and I hear a metal-on-metal sound while pulling into a rest area . . . turns out the coolant hose support bracket (RN part RNN303--first place I found it; see orange arrow in pic below) is totally loose.
So I try to tighten it up; turning it clockwise seems only to make it looser, so I decide it must be reverse thread, and give counterclockwise a try, and then realize it's just stripped. I'm going to go out on a limb and say the aluminum housing (not the steel screw) stripped, although I haven't disassembled things yet.
So I do a Rube Goldberg setup (see below) to get hoses away from pulleys/protect them from the pulleys' aggression, and made it home OK.
I've already determined I'm just plain missing the clip for the water pump hose (RN part RNQ864), which is what should be on top of the bracket that's loose.
Which leads me to three questions:
1) What should I do with the stripped hole in the housing? re-tap it for the next bolt size up? Stick an insert in it and use the same size bolt? Place a thermite grenade on it and walk away? Bear in mind that I don't want to resort to shenanigans like pulling the radiator so I can stick a drill in there, nor do I want to remove the entire timing cover or anything like that. Something cheap, lazy, and effective would be perfect, but I don't want to screw anything up, and so am open to expensive, painful, and effective solutions, but only as a last resort.
1a) Can the water pump pulley (which I reckon I'm going to need to remove regardless of the answer to #1) be removed just by undoing the bolts that hold it to the flange?
2) Once I get the clip bracket tightened into its home, and the proper clip, how do I keep the upper radiator hose away from the water pump pulley? Should I just loosen the hose clamps at both ends and try to rotate it so its elbow is more elevated? Or is there another shield or clip that's meant to keep it out of harm's way?
Thanks in advance,