Lock Carrier

Lock Carrier

Special tools, testers and auxiliary items required

• Drip tray for workshop cranes (VAS 6208)






• Hose clip pliers (VAS 6362)






Removing






- Remove the front noise insulation. Refer to => [ Front Noise Insulation ] Front Noise Insulation.

- Remove the side impact bar. Refer to => [ Impact Member ] Impact Member.

- Place the drip tray for workshop crane (VAS 6208) under the engine.

- Remove the drain plug - 1 - and drain the coolant.

- Open the clamp - 2 - and remove the coolant hose from the radiator.

- Loosen the clamp - 1 - and remove the coolant hose.






• Ignore - arrows A and B -.

- Open the clamp - arrow - and remove the connection from the radiator.






- Loosen the clamp - arrow - and remove the coolant hose.






• Ignore - 1 -.








Danger of personal injury caused by the radiator fan coming on.

• Disconnect all connectors near the fan shroud before starting.

- Push the lock to the rear - arrow -, push the release down and disconnect the connectors - 1 - and - 2 - from the radiator fan.

- Open the clamps - 1 - and - 2 - and remove the connection from the radiator.






- Remove the bolts - arrows - and the air guide - 1 -.






• Ignore - 2 -.

- Release the tabs - arrows A - and remove the left and right air guide - 1 - - arrow B -.






- Remove the air guide - 1 - - arrow - (if equipped).






- Unlock the left and right pins on the radiator and remove them upward - arrows -.






- Have a second technician open the clamps - 1 - in - direction of arrow A - and remove the condenser - 2 - from the mounts on the radiator - arrows B -.






Danger of causing damage to the condenser, the refrigerant lines and the refrigerant hoses

• Do not stretch, kink or bend the refrigerant lines and hoses.

- Move the condenser, with the lines still connected, to the front.

- Remove the left and right bolts - 1 - and then pull the radiator bracket and radiator off the lock carrier - arrow -.






- Remove the radiator, the fan shroud and the front charge air cooling circuit radiator.

- Remove the headlamp mount.

- Remove the bolt - 3 -.






- Disconnect the connectors - 1 and 2 -.

- Disconnect the connector - 4 - from the secondary air injection pump motor (V101) (if equipped).






- Press the release button and remove the secondary air hoses - 1 - and - 2 -.

- Disconnect the hood lock cable at the coupling and place it on the lock carrier. Refer to => [ Hood Release Cable Assembly Overview ] Hood Release Cable Assembly Overview.

• Ignore - 3 -.

- Remove the bolts - 5 and 6 -.






- Have a second technician hold the lock carrier - 4 - and remove the bolts - 1 through 3 -.

- Remove the lock carrier and the impact member mounts with a second technician.

Installation






• Tightening specifications, refer to => [ Lock Carrier with Attachments Assembly Overview ] Lock Carrier With Attachments Assembly Overview, => [ Bumper Cover Assembly Overview ] Bumper Cover Assembly Overview.

Installation is reverse of removal, but note the following:

- Press the front bumper cover mount - 3 - against the headlamp housing - 2 - - arrow -, hold it in this position and then tighten the bolt - 1 -.

• The rib - 4 - on the mount must touch the headlamp housing.

- Install the secondary air injection pump motor.

- Install the radiator, the fan shroud and the front charge air cooling circuit radiator.

- Install the impact member. Refer to => [ Impact Member ] Impact Member.