Radiator (B204i/E)

Radiator (B204i/E)

1.	Remove the charge air cooler (turbo), see .

2.	Remove the front grille.

3.	Detach the oil cooler (certain cars) and suspend it so that the hoses will not be damaged.

4.	Detach the condenser from the radiator (A/C).

5.	Note the radio code if applicable. Disconnect the vent hose and remove the battery.

6.	Open the drain plug and drain the coolant. Unscrew the expansion tank filler cap to speed this up.

7.	Remove the bypass hose together with the intake hose (turbo).

8.	Detach the upper radiator hoses from the radiator.

9.	Unplug the radiator fan electric connections.

10.	Detach the servo pump's oil pipe and the clips for the radiator's venting hose from the radiator crossmember and bend the oil pipe aside.

11.	Remove the radiator fan cowling (2 bolts) and lift it up.

12.	Remove the gearbox oil pipes at the oil cooler, remove the bolt securing the pipes to the cooler and plug the connections (aut.).

13.	Remove the lower radiator hose from the radiator. Remove the clamps securing the radiator to its crossmember and pull the radiator up and out of the rubber mountings so that the clip for the A/C compressor's cable can be removed.

14.	Lift out the radiator.

To fit

1.	Smear the radiator's rubber bushes with vaseline.

2.	Introduce the radiator into position and fit the clamps. Refit the clip for the A/C compressor cable.

3.	Attach the gearbox oil pipes to the oil cooler (aut.). Tightening torque: 25 Nm (18.5 lbf ft) Do not forget the bolt securing the pipes to the radiator.

4.	Check that the radiator drain plug is tightened. Tightening torque: 4 Nm (3 lbf ft) Attach the lower radiator hose to the radiator.

5.	Position the radiator fan cowling on the radiator and tighten the 2 bolts.

6.	Connect the radiator fan and attach the upper radiator hoses.

7.	Fit the clips for the radiator's venting hose to the radiator crossmember and fit the servo pump's oil pipe.

8.	Fit the bypass hose together with the intake hose and delivery pipe between the charge air cooler and throttle body (turbo).

9.	Fill up with coolant and check the system for leaks.

10.	Fit and reconnect the battery.

11.	Check the gearbox oil level and top up as necessary (aut.).

12.	Fit the condenser (A/C).

13.	Fit the oil cooler (certain cars).

14.	Refit the grille.

15.	Fit the charge air cooler (turbo).

16.	Fill up and bleed the system as follows: Note A/C and ACC must be OFF.

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Fill the system up to the MAX level, fit the pressure cap, start the engine and warm it up at varying rpm until the radiator fan starts.

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Switch off the engine and top up as necessary to the MAX level.

17.	Set the car clock and radio code where applicable. Calibrate the ACC.