Radiator Support: Service and Repair
41 33 040 Replacing Modular Front EndSpecial Tools Required:
- 13 5 281
- 13 5 282
NOTE:
The following work steps apply to cars with A/C systems and automatic transmissions:
- Disconnect battery, please refer to: Vehicle/ Starting and Charging/ Battery/ Service and Repair/ Procedures.
- Drain A/C System, please refer to: Vehicle/ Heating and Air Conditioning/ Service and Repair/ Service and Repair
- Drain coolant, please refer to: Vehicle/ Engine, Cooling and Exhaust/ Cooling System/ Coolant/ Service and Repair/ Service and Repair
- Remove underpan of engine compartment, please refer to: Vehicle/ Body and Frame/ Splash Guard/ Service and Repair/ Service and Repair
- Remove front bumper, please refer to: Vehicle/ Body and Frame/ Front Bumper/ Front Bumper Cover/ Fascia/ Service and Repair
- Remove both wheel arch liners, please refer to: Vehicle/ Body and Frame/ Splash Guard/ Service and Repair/ Service and Repair
Removing
- Detach plug connectors from radiator fan (1) for oil cooler and release oil cooler (2) from retaining clip.
This work step applies only to cars with Automatic Transmissions.
Tightening Torque Specifications:
- Remove retaining screw (1) for oil cooler and release oil cooler (2) from retaining clip.
This work step applies only to cars with Automatic Transmissions.
- Postion oil cooler as pictured (1).
- Disconnect both oil cooler connections (2) and remove oil cooler (3).
IMPORTANT!
After removing oil cooler connections, connect special tool 13 4 282 to radiator and special tool 12 5 281 to radiator hoses.
This work step applies only to cars with A/C systems.
Tightening Torque Specifications:
- Release screw (1) securing line to condenser, disconnect line and seal both connections.
- Release screw (2) securing condenser line, disconnect line and seal both connections.
Installation:
- Replace O-ring on both connections.
- Right side. Release ABS wheel speed sensor from clip (1).
- Disconnect plug connector (2) for fog lamp.
- Disconnect horn plug connector (3).
- Lay wiring harness (4) through modular front end into wheel arch.
Tightening Torque Specifications:
- Release screws (5) securing the crumple tubes to the sub frame.
- Repeat the above steps on the left side.
Tightening Torque Specifications:
- Release clamp and detach upper radiator hose (1).
- Unscrew nuts (2) securing the modular front end and the bumper carrier.
- Remove the complete modular front end together with a helper.
Tightening Torque Specifications:
- Remove screws (1) securing modular front end to chassis carriers.
- Remove bumper carrier and chassis carrier (2) from modular front end.
Tightening Torque Specifications:
- Remove retaining screws (1) of condenser and remove condenser.
- Remove dowel pins (3A) release clips (3B) securing upper end of radiator to modular front end.
- Release radiator from lower mountings and remove radiator (4).
- Detach gasket (5) from top edge of modular front end.
- Remove clip (1) securing resonator to modular front end.
- Remove screw (2) securing horn to modular front and remove horn (3). Repeat procedure on opposite side.
- Remove clip (1) for ABS wheel speed sensor from modular front end.
- Remove screw (2) securing adjustable bumper bracket to modular front end and remove bracket (3)
Installation:
- Install screw for adjustable bumper bracket, but do not tighten down yet. This is done only when the bumper is installed.
- Remove screws (4)securing fog lamp and remove fog lamp (5).
- Repeat the above steps on the opposite side.
- Remove air intake ducts (1, 2, 3, and 4) from modular front end.