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Radiator

Radiator

To remove


1. Remove the upper engine cover.


2. Remove the front grille.

3. Remove the light clusters and the headlamps.

4. Loosen and move aside the air deflectors by the condenser.


5. Open the expansion tank pressure cap and release any overpressure.

6. Disconnect the battery, remove the air venting hose and lift out the battery.

7. Loosen the battery tray, cut of the cable ties for the wiring and remove the battery tray.

8. Disconnect the hose from the throttle body and plug it. Remove the hose from between the charge air cooler and charge air pipe.


9. Remove the power steering fluid pipe from the brackets on the radiator cross member and below the battery tray.

10. Disconnect the vent hose from the radiator crossmember, cut of the cable ties and move aside the hose.

11. Unplug the radiator fan connector.

12. Remove the power steering fluid reservoir from the bracket and move aside the reservoir.


13. Raise the car, remove the lower cover and the air shields.

14. Place a receptacle under the radiator and drain the coolant.

15. Remove the condenser retaining bolts.


16. Lower the car, disconnect the lower coolant hose from the radiator and disconnect the upper coolant hose from the radiator and the thermostat housing.

Important

There is still plenty of coolant in the engine, always have a suitable container under the engine when working on the cooling system.


17. Remove the vent hose from the radiator.


18. Remove the bolts securing the EGR valve and move the valve to one side

19. Unhook the condenser from the radiator.

20. Cut the cable tie from the lower coolant hose. Remove the radiator fan cowling from the radiator.


21. Remove the clamps that secure the radiator to the radiator crossmember and remove the fan cowling.

22. Remove the second hose from the charge air cooler.

23. Remove the A/C compressor cable from the radiator and remove the A/C pipe from the radiator crossmember.

24. Lift up the radiator.

Important

Check that nothing is loose or damaged.



To fit


1. Check that the radiator drain plug is tightened and apply acid-free petroleum jelly to the rubber bushings.

2. Fit the radiator.

Important

Check that nothing is loose or damaged.



3. Fit the fan cowling to the radiator and tighten the bolts.

Important

Check that nothing is loose or damaged.


4. Connect the lower coolant hose and attach a cable tie to the radiator fan. Secure the A/C compressor cable to the radiator.

5. Hook the condenser onto the radiator.

6. Raise the car and refit the A/C pipe into its bracket.

7. Fit the condenser.


8. Refit the air shields and the lower cover. Lower the car.

9. Fit the power steering fluid pipe in the brackets on the radiator crossmember and below the battery tray, and refit the power steering fluid reservoir.


10. Reconnect the vent hose and fixate it to the radiator crossmember.

11. Connect the hoses to the charge air pipe and throttle body.

12. Plug in the radiator fan connector.

13. Fit the EGR valve.

14. Connect the upper coolant hose and fit the hose clamp.

15. Fit the battery tray and fixate the wiring.


16. Refit and reconnect the battery. Connect the venting hose.

17. Fit the air shields by the condenser.

18. Fit the headlamps and the light clusters.

19. Refit the grille.


20. Adjust the clock in the car and press 5 times on the remote control lock/unlock button.

21. Fill with coolant, check the integrity of the system and bleed it as follows:

Note

AC/ACC must be off.


Connect exhaust hoses to both the engine exhaust system and the auxiliary heater exhaust system and start the engine.

Start the parking heater with the diagnostic tool (Body - SID - Activate - Heater). The parking heater stops when the engine temperature has reached 80°C or on exiting the parking heater menu.

Check that there is a continuous flow of coolant in the hose from the thermostat housing to the expansion tank. Rev up the engine briefly to ensure circulation of the fluid.

Run the engine until the thermostat has opened.

22. Shut off the engine and top up the cooling system if needed.

23. Fit the engine cover.