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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 (A) to relieve pressure and then retighten the cap.


2. Remove the upper engine cover and insulation.

3. Remove the battery cover.

4. Raise the car.

5. Remove the Spoiler shield, front .

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


7. Detach the turbocharger delivery pipe's hose (A) and remove the pipe's bolt (B).


8. Lower the car.

9. Remove Upper radiator member and Front bumper shell .

10. Detach the turbocharger delivery hose (A) from the throttle body.


11. Detach the turbocharger delivery pipe (B) from the fan cowling. Remove the pipe and hose assembly.

12. Detach the upper radiator hose (A).


13. Detach the bleeder hose from the radiator (B).

14. Detach the turbo delivery pipe and hose from the turbocharger outlet (A).


15. Aut: Detach the upper coolant pipe from the automatic transmission using 87 92 806 Removal tool, oil pipe, automatic transmission .

16. Remove the bolt (A) holding the turbocharger delivery pipe in place (right side).


17. Remove the bolts (B) holding the fan cowling in place.

18. Remove the bolts (C) holding the top edge of the charge air cooler.

19. Remove the radiator cover (D).

20. Guide a 83 95 212 Strap (A) over the fan cowling and through the engine's lifting eye. Secure the fan cowling.


21. Insert two bolts in the radiator member mounting (B) and position two 83 95 212 Straps (C) on opposite sides of the charge air cooler and condenser. Guide the straps around the bolts and secure.

22. Raise the car.

Important

It is important to secure radiators to prevent damage to the cooling fins.


23. Aut: Detach the lower coolant pipe from the automatic transmission using 87 92 806 Removal tool, oil pipe, automatic transmission .

24. Remove the plastic cover on the right side (A).


25. Detach the turbocharger delivery hose (A).


26. Remove the lower bolt (B) on the turbo pipe.

27. Detach the lower coolant connection (C).

28. Remove the lower mounting of the radiator core (D) on the right side.

29. Lower the radiator core slightly to access the bolts of the dryer filter.

30. Detach the dryer filter from the radiator (E).

31. Remove the lower mounting of the radiator core (A) on the left side.


32. Carefully lower the radiator.


To fit


1. Raise the radiator from underneath.

2. Fit the lower mounting (A) of the radiator core on the left side.


3. Fit the dryer filter holder (E) to the radiator.


4. Fit the lower mounting of the radiator core (D) on the right side.

5. Check that the charge air cooler and fan cowling sit in their lower mountings.

6. Remove the straps.

7. Attach the lower coolant connection (C) to the radiator.

8. Fit the lower bolt (B) on the turbo pipe.

9. Attach the turbocharger delivery hose (A).

10. Lower the car.

11. Remove the strap and fit the fan cowling (B).


12. Fit the charge air cooler (C).

13. Fit the radiator core cover (D).

14. Fit the bolt (A) holding the turbocharger delivery pipe in place.

15. Fit the turbocharger delivery pipe and hose to the turbocharger outlet (A).

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.



16. Fit the plastic cover (A) on the right side.


17. Fit the upper radiator hose (A).


18. Fit the bleeder hose (B) to the radiator.

19. Fit the turbocharger delivery hose (A) to the throttle body and the clip to the coolant hose. Fit the upper bolt (B) to the pipe.


20. Aut: Fit the upper coolant pipe to the automatic transmission.

21. Raise the car.

22. Aut: Fit the lower coolant pipe to the automatic transmission.

23. Attach the turbocharger delivery pipe's hose (A) and fit the pipe's bolt (B).


24. Lower the car.

25. Fit Upper radiator member and bumper shell.

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

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

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