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Radiator

Radiator

To remove

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Undo the expansion tank cap to release pressure and then retighten the cap.


2. Remove the upper engine cover, insulation and battery cover.

3. Raise the car.

4. Remove the spoiler shield.


5. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant.


6. Remove the turbocharger delivery pipe hose and the pipe screw from the radiator.


7. Lower the car.

8. Remove the Front bumper shell .

9. Remove the right-hand headlight.


10. Disconnect the A/C pipe mounting and boost pressure valve from the radiator member.


11. Remove the upper radiator member.

Warning

Ensure that you do not place the top radiator bracket on the battery positive terminal, otherwise there is a risk of short-circuit/fire.



12. Remove the turbocharger delivery hose from the throttle body, the clip from the coolant hose and the turbocharger delivery pipe from the fan cowling. Remove the pipe and hose complete.


13. Remove the turbo delivery pipe and hose from the turbocharger outlet.


14. Remove the upper radiator hose.


15. Remove the air exhaust hose from the radiator.

16. Remove the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold.

17. Remove the upper radiator mounting and rubber bushings.


18. Hold away the A/C hose using 83 95 212 Strap .


19. Remove the electrical connection from the fan cowling.

20. Remove the bolts and lift up the fan cowling.

21. Remove the cover.


22. Remove the intake manifold from the air cleaner can (air intake in front of radiator).

23. Remove the turbocharger delivery pipe with hose.


24. Undo the desiccant container from the radiator.


25. Remove the lower coolant hose from the radiator.


26. Hang up the charge air cooler and condenser using 83 95 212 Strap to the radiator member stay.

27. Remove the radiator mountings from the subframe.

28. Remove the radiator from the charge air cooler and extract the radiator downwards under the car.



To fit


1. Fit the radiator from below.


2. Hook the radiator to the charge air cooler and fasten it.

3. Fit the mountings to the subframe, torque, and the radiator pins.


4. Remove the strap.

5. Fit the lower coolant hose.

6. Fit the desiccant container to the radiator.


7. Fit the charge air pipe with hose to the radiator.


8. Fit the intake manifold to the air can. The fastening lug must be behind the wiring harness.


9. Fit the cover.

10. Fit the fan cowling.


11. Remove the strap.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


12. Fit the turbocharger delivery pipe and hose to the turbocharger outlet.


13. Fit the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold.


14. Fit the electrical connections to the fan.

15. Fit the upper radiator hose.

16. Fit the air exhaust hose to the radiator.

17. Fit the turbocharger delivery pipe to the throttle body and the clip to the coolant hose. Fit the upper bolt.


18. Fit the upper radiator mountings and rubber bushings.


19. Fit the radiator member.


20. Fit the A/C pipe and boost pressure valve.


21. Fit the right-hand headlight.


22. Fit the Front bumper shell .

23. Raise the car.

24. Fit the turbocharger delivery pipe hose and pipe to the radiator.


25. Fit the front spoiler shield.


26. Lower the car.

27. Pressure test the cooling system, see Cooling system, pressure testing .

28. Fill with coolant, see Filling and bleeding the cooling system, Z19 .

29. Fit the insulation, upper engine cover and battery cover.