Radiator (B205L/R, B235 R)
|
|
Radiator (B205L/R, B235 R)
|
|
1.
|
Disconnect the vent hose from the battery.
Disconnect the positive and negative battery cables and remove the battery. Note the radio code where applicable.
|
|
2.
|
Unplug the radiator fan electric connections.
|
|
3.
|
Remove the top engine cover.
|
|
4.
|
Remove the charge air pipe and bypass pipe with valve, keep the O-ring from the connection to the turbocharger intake pipe.
|
|
5.
|
Remove the heat shield over the exhaust manifold.
|
|
6.
|
Remove the power steering system's fluid reservoir.
|
|
7.
|
Undo the oil pipe for the power steering servo pump, the clip for the A/C expansion tank and the clip for the radiator vent hose from the radiator crossmember and bend the oil pipe to one side.
|
|
8.
|
Remove the bracket from the battery tray and bend it aside.
|
|
9.
|
Remove the radiator fan cowling, 2 bolts.
Tilt the radiator fan cowling, twist up and lift out.
|
|
10.
|
Place a receptacle under the car and remove the gearbox oil pipe on the oil cooler. Remove the screw securing the pipe to the cooler and plug the connections (aut).
|
|
11.
|
Remove the front grille.
|
|
12.
|
Remove headlamps and light clusters.
|
|
13.
|
Remove the 2 air shields.
|
|
15.
|
Open the expansion tank pressure cap to release system pressure.
|
|
17.
|
Remove the lower air shields.
|
|
18.
|
Drain the coolant by connecting a hose and opening the drain plug. Collect the coolant in a suitable receptacle.
|
|
19.
|
Tighten the drain plug.
|
|
20.
|
Unbolt the bottom of the charge air cooler, 2 bolts.
|
|
21.
|
Unbolt the bottom of the oil cooler, 3 bolts. Bend the oil cooler aside and secure with a cable tie or similar.
|
|
22.
|
Unbolt the bottom of the condenser, 2 bolts.
|
|
23.
|
Detach the outlet hose from the turbocharger.
|
|
24.
|
Detach the outlet hose from the charge air cooler.
|
|
25.
|
Lower the car to the floor.
|
|
26.
|
Detach the upper hose from the radiator.
|
|
27.
|
Detach the lower hose from the radiator.
|
|
28.
|
Remove the clips securing the radiator to the radiator crossmember and pull the radiator up out of the rubber mountings.
|
|
29.
|
Unhook the condenser from the mountings on the radiator.
|
|
30.
|
Tilt the radiator away from the radiator crossmember and disconnect the vent from the expansion tank.
|
|
31.
|
Cut off the clip securing the A/C compressor cable to the radiator.
|
|
32.
|
Lift out the radiator.
|
|
1.
|
Lubricate the radiator upper rubber bushes with non-acidic vaseline, part no. 30 06 665, or the equivalent.
|
|
2.
|
Lift the radiator into place but do not press it home.
|
|
3.
|
Fit the bleed hose to the expansion tank.
|
|
4.
|
Hook the condenser onto the mountings on the radiator.
|
|
5.
|
Press the radiator home and fasten the 2 clips that secure the radiator to the radiator member.
|
|
6.
|
Fasten the A/C compressor's lead to the radiator with a new clip.
|
|
7.
|
Attach the radiator's lower hose.
|
|
8.
|
Attach the turbocharger's outlet hose and the charge air cooler's outlet hose.
|
|
10.
|
Bolt the bottom of the condenser in place, 2 bolts.
|
|
11.
|
Remove the cable tie and fit the oil cooler, 3 bolts.
|
|
12.
|
Bolt the bottom of the charge air cooler in place, 2 bolts.
|
|
13.
|
Fit the two lower air shields.
|
|
14.
|
Make sure the cooling system drain plug is tight. Fit the lower air shields and lower the car.
|
|
15.
|
Fit both air shields (by the side of the condenser).
|
|
16.
|
Fit the light clusters and headlamps.
|
|
17.
|
Fit the horn and front grille.
|
|
18.
|
Attach the gearbox oil pipes to the oil cooler (aut.).
Tightening torque 25 Nm (19 lbf ft)
|
|
19.
|
Fit the screw securing the pipe to the radiator
Tightening torques
|
|
20.
|
Lift the radiator fan cowling into place and fit the 2 bolts.
|
|
21.
|
Attach the radiator's upper hose.
|
|
22.
|
Mount the bracket on the battery tray.
|
|
23.
|
Fit the power steering system's fluid reservoir.
|
|
24.
|
Fit the oil pipe for the power steering servo pump and the clips for the radiator vent hose as well as the clip for the A/C expansion tank.
|
|
25.
|
Plug in the radiator fan's plugs.
|
|
26.
|
Fit the heat shield over the exhaust manifold.
|
|
27.
|
Fit the charge air pipe.
|
|
28.
|
Fit the bypass pipe with valve. Use a new O-ring for the connection to the turbocharger intake pipe.
|
|
29.
|
Fit the top engine cover.
|
|
30.
|
Fit the battery and connect its vent hose.
|
|
31.
|
Fill up with coolant. For the correct mixture, see
Cooling system
.
Close the filler cap.
|
|
32.
|
Bleed the system as follows:
|
Note
|
|
A/C and ACC must be OFF.
|
Fill the cooling system to MAX level. Close the cap on the expansion tank, start the engine and warm it up at various engine speeds until the radiator fan starts. Carefully open the cap and top up to MAX.
|
|
33.
|
Raise the car to check for oil or coolant leakage.
|
|
34.
|
Lower the car and top up with coolant / transmission fluid (aut) as necessary
|
|
35.
|
Set the clock and radio code where applicable.
|
