Radiator, Replacing
Radiator, replacing
Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Caution! If the car is equipped with an earlier version of the air conditioning (AC) hose (1), continue according to this method. If the car is equipped with a later version of the air conditioning (AC) hose (2), proceed to the new method. See: Radiator, replacing Radiator, Replacing.
Remove the battery lead. See Battery, disconnecting Battery Disconnecting.
Drain the A/C system. See Refrigerant, draining Refrigerant, Draining.
Removing the skid plate
Remove the 6 screws.
Lift up and slide the plate forward.
Remove the protective plate.
Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Draining coolant
Block the lower hose with lock grip pliers.
Install a hose on the nipple at the radiator.
Feed the hose down to a container.
Open the nipple and drain off the coolant.
Removing the cable duct and air duct
Remove the screw for the cable duct. Place the cable duct on the sub-frame.
Pull the air duct from the clips on the sub-frame.
Removing the oil cooler hoses
Applies only to cars with automatic transmissions:
Remove the lower oil cooler hose from the cooler unit.
Plug the openings in the hose and radiator.
Note! Collect the oil from the oil cooler in a container.
Lower the car. Remove the upper oil cooler hose from the cooler unit.
Plug the openings in the hose and radiator.
Removing the upper coolant hoses
Remove:
- the evacuation hose from the expansion tank and clip mounting
- the upper radiator hose.
Removing the charge air pipe/hose
Applies only to cars with a turbocharger (TC):
Disconnect the charge air pipe from the charge air cooler (CAC) on the left-hand side. If necessary, use a hot air gun to make removal easier.
Remove the clamp. Remove the charge air hose on the right-hand side from the charge air cooler (CAC).
Removing the right-hand headlamp
Headlamps removing.
Pull the locking plate straight up.
Disconnect the connector.
Remove the headlamp.
Removing the air conditioning (A/C) pipe
Remove from the left-hand side:
- the screw
- the air conditioning (A/C) pipe.
Seal the openings on the pipe and condenser.
Remove from the right-hand side:
- the connector.
Raise the car.
Remove:
- the screw
- the air conditioning (A/C) pipe.
Seal the openings on the pipe and receiver.
Hint: Pull down and hang up the left-hand pipe so that the hose is positioned above the sub-frame.
Removing the lower engine coolant hose
Slacken off the hose clamp. Remove the hose from the radiator.
Fold the hose out of the way.
Removing the radiator assembly
Note! Two people are required for this procedure.
Hold up the air conditioning aggregate. Slacken off the two mounting screws.
Pull down the air conditioning aggregate carefully.
Note! Ensure that no hoses are trapped when removing the air conditioning aggregate.
Removing the engine cooling fan (FC)
Remove:
- the screws
- the evacuation hose from the clip mountings
- the engine cooling fan (FC).
Removing the radiator
Remove:
- the screws
- the radiator.
Transferring components
Transfer the evacuation hose.
Applies to cars equipped with an extra oil cooler:
Transfer the oil cooler.
Installing the radiator
Position the radiator over the condenser and the charge air cooler (CAC).
Install the screws. Tighten to 10 Nm.
Installing the engine coolant fan (FC)
Install:
- the engine cooling fan (FC)
- the screws. Tighten to 10 Nm
- the evacuation hose in the clip mountings.
Installing the cooler unit
Note! Two people are required for this procedure.
Lift up the air conditioning aggregate. Install the two mounting screws. Tighten to 24 Nm.
Note! Ensure that the air conditioning aggregate is positioned correctly in the locating pins on top of the aggregate.
Note! Ensure that no hoses are trapped when installing the air conditioning aggregate.
Installing the lower engine coolant hose
Install the hose. Tighten the clamp.
Remove the lock grip pliers.
Installing the air conditioning (A/C) pipe
Hint: Lubricate the O-rings using compressor oil.
Install on the right-hand side:
- the air conditioning (A/C) pipe. Use a new O-ring
- the screw. Tighten to 10 Nm.
Lower the car.
Connect the connector to the receiver.
Install on the left-hand side:
- the air conditioning (A/C) pipe. Use a new O-ring
- the screw. Tighten to 24 Nm.
Vacuum pump the air conditioning (A/C) system. See Vacuum pumping Vacuum Pumping.
Installing the right-hand headlamp
Install:
- the connector
- headlamps
- the locking plate.
Installing the upper engine coolant hoses
Install:
- the upper radiator hose
- the evacuation hose on the expansion tank and clip mounting.
Installing the charge air pipe/hose
Install:
- the charge air hose on the right-hand side
- the charge air pipe on left-hand side.
Tighten the clamps.
Installing the oil cooler hoses
Applies only to cars with automatic transmissions:
Install the upper oil cooler hose.
Use a new O-ring. Raise the car.
Install the lower oil cooler hose.
Use a new O-ring.
Installing the cable duct and air duct
Position the cable duct.
Install the screw. Tighten to 10 Nm.
Install the air duct using the clip on the sub-frame.
Installing the skid plate
Move the skid plate up into the bumper wraparound.
Press forwards until the mounting brackets engage in the sub frame.
Install the screws. Tighten to 50 Nm.
Finishing
Fill the A/C system. See Refrigerant, filling Refrigerant, Filling.
Check for leaks. See Leak tracing, fluorescent tracing agent/UV lamp Leak Tracing, Fluorescent Tracing Agent/UV Lamp or Leak tracing, electronic leak tracer Leak Tracing, Electronic Leak Tracer.
Install the battery lead.
Top up the coolant.
Install the cap on the expansion tank.
Run the engine until the thermostat has opened.
Stop the engine. Top up if necessary.
Check for leaks.