Radiator, Remove and Install (with Air
Conditioning)
Remove
2. |
Disconnect battery
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Detach ground connection from ground terminal
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3. |
Detach radiator grille (2)
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Detach 4x body-bound rivets (1)
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Release 6x lugs from front panelling
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4. |
Raise vehicle by half its height
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5. |
Detach front panelling (1)
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Remove 5x body-bound rivets (3)
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6. |
Remove front panelling
Note: Use a second
person
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Push front panelling upwards in direction of arrow and pull out
of bracket
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Detach outside temperature sensor
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7. |
Raise vehicle by half its height
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8. |
Remove lower engine cover and right engine splash guard
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9. |
Place collecting basin underneath.
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10. |
Drain coolant
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Open drain bolt on radiator (1)
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11. |
Detach wiring harness from radiator
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Disconnect wiring harness plug for fan motor (1)
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12. |
Detach refrigerant line (1) from radiator
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13. |
Detach compressor wiring harness (2) from radiator
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14. |
Detach right coolant hose (3) from radiator
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15. |
Detach 2x vacuum lines (5) from radiator
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16. |
Secure radiator at upper radiator brackets (1)
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Insert 2x suitable tools
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17. |
Remove lower radiator bracket (1)
Note: Note: brackets
are not the same
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18. |
Lower vehicle by its full height
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19. |
Remove battery
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Detach positive terminal (3) from positive pole
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20. |
Remove pre-glow system control unit (1)
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Pull pre-heating system control unit out of bracket in
direction of arrow
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Disconnect wiring harness connector.
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21. |
Detach expansion tank coolant hose (2) from radiator
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22. |
Detach left coolant hose (1) from radiator
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23. |
Detach charge air hose (1) from charge air pipe.
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24. |
Detach fan housing from radiator
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Unclip charge air pipe (1)
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25. |
Raise vehicle by half its height
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26. |
Suspend condenser from top of front panel
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27. |
Detach condenser with auxiliary fan and intercooler from
radiator
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Unscrew 5x bolt (1), (2), (3) and (5)
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Pull intercooler from bracket (4)
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28. |
Remove radiator
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Remove 2x fuses from bracket
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Install
29. |
Modify attaching parts
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Charge air pipe bracket
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Radiator holder rubbers
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30. |
Install radiator
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Insert 2x fuses in bracket
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31. |
Attach condenser with auxiliary fan and intercooler to
radiator
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Insert condenser into bracket
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Important: Insert screw with
thread locking compound
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Tighten 5x bolt 5 Nm
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32. |
Detach condenser from top of front plate
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33. |
Raise vehicle by half its height
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34. |
Attach 2x vacuum lines from radiator
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35. |
Attach right coolant hose to radiator
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36. |
Attach compressor wiring harness to radiator
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37. |
Install lower radiator bracket
Note: Note: brackets
are not the same
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Screw in 4x bolts 15 Nm
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38. |
Remove 2x retainers from upper radiator bracket
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39. |
Attach refrigerant line to radiator
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40. |
Attach wiring harness to radiator
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Connect wiring harness plug
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41. |
Install lower engine cover and right engine splash guard
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Install 2x body-bound rivets
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42. |
Lower vehicle by half its height
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43. |
Insert front panelling
Note: Use a second
person
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Clip in outside temperature sensor
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44. |
Fit front panelling
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Install 5x body-bound rivets
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45. |
Lower vehicle by half its height
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46. |
Attach fan housing to radiator
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Clip in charge air pipe
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47. |
Attach charge air hose to charge air pipe
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48. |
Attach left coolant hose to radiator
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49. |
Attach expansion tank coolant hose to radiator
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50. |
Install pre-glow system control unit
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Connect wiring harness plug
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Clip to battery support
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51. |
Install battery
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Attach positive connection to positive terminal
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52. |
Connect battery
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Attach ground connection to ground terminal
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53. |
Install radiator grille
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Clip into front panelling
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Install 4x body-bound rivets
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54. |
Top up coolant or ensure correct quantity is present.
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55. |
Program volatile memories
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