|
Removing and installing charge air pipe
 Remove
| 2. |
Disconnect battery
| • |
Detach earth connection from earth terminal
|
|
| 3. |
Detach radiator grille (2)
| • |
Detach 4x body-bound rivets (1)
|
| • |
Release 6x lugs from front panelling
|
|
|
|
| 4. |
Raise vehicle by half its height
|
| 5. |
Detach front panelling (1)
| • |
Remove 5x body-bound rivets (3)
|
|
| 6. |
Remove front panelling
Note: Second
mechanic
| • |
Push front panelling upwards in direction of arrow and pull out
of bracket
|
| • |
Detach outside temperature sensor
|
|
|
|
| 7. |
Raise vehicle by half its height
|
| 8. |
Detach the lower engine cover and right engine splash guard
|
| 9. |
Place collecting basin underneath.
|
| 10. |
Drain coolant
| • |
Open drain bolt on radiator (1)
|
|
|
|
| 11. |
Detach wiring harness from radiator
| • |
Detach wiring harness plug (1) from fan motor
|
|
|
|
| 12. |
Detach refrigerant line (1) from radiator
|
| 13. |
Detach compressor wiring harness (2) from radiator
|
| 14. |
Detach right coolant hose (3) from radiator
|
| 15. |
Detach 2x vacuum lines (5) from radiator
|
|
|
| 16. |
Secure radiator at upper radiator brackets (1)
| • |
Insert 2x suitable tools
|
|
|
|
| 17. |
Remove lower radiator bracket (1)
Note: Note: brackets
are not the same
|
|
|
| 18. |
Lower vehicle by its full height
|
| 19. |
Remove battery
| • |
Detach positive terminal (3) from positive pole
|
|
|
|
| 20. |
Remove control unit, pre-heating system (1)
| • |
Pull pre-heating system control unit out of bracket in
direction of arrow
|
| • |
Disconnect wiring harness connector.
|
|
|
|
| 21. |
Detach expansion tank coolant hose (2) from radiator
|
| 22. |
Detach left coolant hose (1) from radiator
|
|
|
| 23. |
Detach charge air hose (1) from charge air pipe.
|
|
|
| 24. |
Detach fan housing from radiator
| • |
Unclip charge air pipe (1)
|
|
|
|
| 25. |
Raise vehicle by half its height
|
|
| 26. |
Suspend condenser from top of front panel
|
| 27. |
Detach condenser with auxiliary fan and intercooler from
radiator
| • |
Unscrew 5x bolts (1 to 3) and (5)
|
| • |
Pull intercooler from bracket (4)
|
|
|
| 28. |
Remove radiator
| • |
Remove 2x fuses from bracket
|
|
| 29. |
Remove charge air pipe (1)
| • |
Pull charge air pipe out of charge air hose
|
|
|
|
Install
| 31. |
Install radiator
| • |
Insert 2x fuses in bracket
|
|
| 32. |
Attach condenser with auxiliary fan and intercooler to
radiator
| • |
Insert condenser into bracket
|
|
| 33. |
Detach condenser from top of front plate
|
| 34. |
Raise vehicle by half its height
|
| 35. |
Attach 2x vacuum lines from radiator
|
| 36. |
Attach right coolant hose to radiator
|
| 37. |
Attach compressor wiring harness to radiator
|
| 38. |
Install lower radiator bracket
Note: Note: brackets
are not the same
| • |
Screw in 4x bolts 15 Nm
|
|
| 39. |
Remove 2x retainers from upper radiator bracket
|
| 40. |
Attach refrigerant line to radiator
|
| 41. |
Attach wiring harness to radiator
| • |
Fix wiring harness plug
|
|
| 42. |
Install lower engine cover and right engine splash guard
|
| 43. |
Lower vehicle by half its height
|
| 44. |
Insert front panelling
Note: Second
mechanic
| • |
Clip in outside temperature sensor
|
|
| 45. |
Fit front panelling
| • |
Install 5x body-bound rivets
|
|
| 46. |
Lower vehicle by half its height
|
| 47. |
Attach fan housing to radiator
| • |
Clip in charge air pipe
|
|
| 48. |
Attach charge air hose to charge air pipe
|
| 49. |
Attach left coolant hose to radiator
|
| 50. |
Attach expansion tank coolant hose to radiator
|
| 51. |
Install control unit - pre-heating system
| • |
Fix wiring harness plug
|
| • |
Clip to battery support
|
|
| 52. |
Install battery
| • |
Attach positive connection to positive terminal
|
|
| 53. |
Connect battery
| • |
Attach ground connection to ground terminal
|
|
| 54. |
Install radiator grille
| • |
Clip into front panelling
|
| • |
Install 4x body-bound rivets
|
|
| 55. |
Top up coolant or ensure correct quantity is present.
|
| 56. |
Program volatile memories
|
|
