Procedures
Removing and installing radiatorPreliminary work for removing radiator
1. Remove air guides in front of radiator.
Note: The air-conditioning condenser remains in the vehicle. The air-conditioning system is not opened.
2. Detach air-conditioning condenser from side radiator and allow it to hang freely. To do this, remove hexagon-head sheet metal screw between air-conditioning condenser and side radiator and pull air-conditioning condenser out of side brackets.
Removing radiator
1. Remove the vent line at the top of the side radiator. To do this, press the lock and pull the line off the support -1-. Pull the vent line out of the holder -2-.
2. Remove cable plug from fan motor -arrow-. To do this, press cable plug together (relieve plug), open the release and disconnect the cable plug.
3. Remove M6 x 16 fastening screw (outer torx) on hose holder arrow-.
WARNING: Danger of scalding from hot pressurized coolant.
^ Only work on the coolant system when the engine is "cool".
^ Wear protective gloves and goggles.
WARNING: Coolant is corrosive and hazardous to health.
^ Skin and eye irritation
^ Wear protective gloves and goggles.
^ If you come into contact with coolant, wash off immediately with plenty of warm water.
Note: Despite the fact that the coolant has been drained, residual amounts of coolant can still emerge at the joints during removal. Have sufficient collecting containers and cloths at hand.
4. Disconnect the two coolant hoses from the supports for the side radiator -arrows-. To do this, loosen the spring-band clamps from the front and push them on to the supports.
5. Open up the coolant hoses at the supports using a screwdriver and allow the coolant hoses to drain -arrow-. Pull coolant hoses off the supports.
6. Remove M8 x 25 fastening screw on bracket from below at the body -arrow-.
7. Undo two M8 fastening nuts on the bracket in the wheel housing at the side wall -arrows-. Carefully remove side radiator complete with bracket to the side. Collect remaining coolant from the hoses and side radiator. Air-conditioning condenser remains in installation position.
8. When the side radiator is removed, remove the sheet metal clips and washers for the bracket -arrows-. Carefully pull the side radiator upwards out of the bracket.
9. Remove two hexagon-head sheet metal screws at the side -1 - and lift cooling fan housing with rear air guide out of the tabs on the side radiator -2-.
Installing radiator
Note: The air-conditioning condenser remains in the vehicle. The air-conditioning system is not opened.
1. Fit cooling fan housing with rear air guide on side radiator. To do this, push side tabs of cooling fan housing into the brackets for the side radiator -2-, move housing into installation position and fit with two fastening screws -1-.
2. Push radiator module into the radiator bracket. Make sure that the radiator is positioned correctly in the side guide and in the lower bores. Fit washers and sheet metal clips on the lower fastening pins of the radiator in such a way that the sheet metal clips engage correctly into the pins -arrows-.
3. Move side radiator with bracket into installation position. Make sure that the hose holder for the coolant hoses is inserted correctly into the side bracket. Push side radiator with bracket on to the studs on the side member and insert fastening screw M6 x 16 (outer torx) for the hose holder -arrow-.
4. Position the M8 fastening nuts on the body studs -arrows-.
5. Fit fastening screws to the body from below. Tightening torque 23 (17) Nm (ft. lbs.) -arrow-.
6. Tighten the fastening nuts on the body studs. Tightening torque 23 (17) Nm (ft. lbs.). Tighten fastening screw M6 x 16 (outer torx) for hose holder. Tightening torque 10 (7.5) Nm (ft. lbs.).
7. Push spring band clamps on to radiator flanges and fit radiator hoses to the flanges. Move engaged spring band clamps into installation position and loosen using a water-pump pliers (use a screwdriver as well, if necessary) and then fasten again -arrows-.
8. Fit radiator vent line to the flange -1- and clip vent line into the plastic holder -2-.
9. Connect cable plug for fan motor -arrow-.
Subsequent work for installing radiator
1. Fit air guide in front of radiator.