Radiator, Z19DTR
Radiator, Z19DTR |
To remove |
|
1. |
Undo the expansion tank cap (A) to relieve pressure and then retighten the cap.
|
2. |
Remove the upper engine cover (B) and insulation.
|
3. |
Remove
Upper radiator member, Z19DTR
|
4. |
Raise the car.
|
5. |
Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant.
|
6. |
Undo the turbocharger delivery pipe's hose clip (A) and remove the pipe's bolt (B).
|
7. |
Lower the car.
|
8. |
Remove the turbo delivery hose's hose clip (A) at the throttle body and the turbo delivery pipe's screw (B) from the fan cowling. Remove the pipe and hose assembly.
|
9. |
Detach the upper radiator hose (A) and the bleeder hose (B) from the radiator and move them aside.
|
10. |
Aut: Detach the upper coolant pipe from the automatic transmission using
87 92 806 Removal tool, oil pipe, automatic transmission
.
|
11. |
Remove the radiator cover (C).
|
12. |
Fit a
83 95 212 Strap
(A) around the fan cowling and in the engine's lifting eye.
|
13. |
Insert bolts (B) in the radiator member mounting and fit two
83 95 212 Straps
(C) on either side of the charge air cooler and condenser.
|
14. |
Raise the car.
|
15. |
Remove the lower mounting of the radiator core (A).
|
16. |
Undo the hose clip (B) of the charge air cooler.
|
17. |
Lower the car.
|
18. |
Remove the hose clips (A).
|
19. |
Remove the right headlamp's bolts (B) and undo the connector (C).
|
20. |
Remove the bolt (A) to the turbocharger intake manifold holder.
|
21. |
Remove the bolts (B) of the crankcase ventilation pipe.
|
22. |
Unplug the connector (C) of the camshaft position sensor.
|
23. |
Remove the bolts of the turbocharger delivery pipe (A) and the bolts of the holder (B).
|
24. |
Raise the pipe slightly and remove the hose clip (C) of the air hose.
|
25. |
Remove the bolts (A) holding the fan cowling in place.
|
26. |
Raise the car.
|
27. |
Aut:
Detach the lower coolant pipe from the automatic transmission using
87 92 806 Removal tool, oil pipe, automatic transmission
.
|
28. |
Remove the nut (A) of the plastic cover on the right side.
|
29. |
Remove the lower coolant connection (B).
|
30. |
Remove the bolt (C) of the A/C pipe bracket.
|
31. |
Lower the radiator core slightly to access the bolts of the dryer filter.
|
32. |
Remove the dryer filter bolts (D).
|
33. |
Remove the bolts (A) holding the top edge of the charge air cooler.
|
34. |
Make sure that the radiator has clearance at the A/C pipe and dryer filter. Carefully lower the radiator.
|
To fit |
1. |
Carefully position the radiator from underneath. Transfer the rubber damper (replace as necessary).
|
2. |
Check that the charge air cooler and fan cowling sit in their lower mountings.
|
3. |
Undo the strap (A) around the fan cowling.
|
4. |
Fit the fan cowling screws (A)
|
5. |
Fit the bolts (A) holding the top edge of the charge air cooler.
|
6. |
Raise the car.
|
7. |
Fit the dryer filter bolts (D).
|
8. |
Fit the bolt (C) of the A/C pipe bracket.
|
9. |
Fit the lower coolant connection (B).
|
10. |
Fit the nut (A) of the plastic cover.
|
11. |
Lower the car.
|
12. |
Fit the hose clip (C) and reposition the turbocharger delivery pipe. Replace the O-rings as necessary.
|
13. |
Fit the bolts of the turbocharger delivery pipe (A) and the bolts of the holder (B).
|
14. |
Plug in the connector (C) of the camshaft position sensor.
|
15. |
Fit the bolts (B) of the crankcase ventilation pipe.
|
16. |
Fit the bolt (A) to the turbocharger intake manifold holder.
|
17. |
Plug in the connector of the right headlamp (C) and fit the bolts (B).
|
18. |
Fit the hose clips (A).
|
19. |
Raise the car.
|
20. |
Fit the hose clip (B) to the charge air cooler.
|
21. |
Fit the lower mounting of the radiator core (A).
|
22. |
Undo the straps (C) around the charge air cooler/condenser and remove the bolts (B).
|
23. |
Aut:
Fit the upper coolant pipe to the automatic transmission.
|
24. |
Fit the radiator cover (C).
|
25. |
Attach the upper radiator hose (A) and the bleeder hose (B) to the radiator.
|
26. |
Fit the hose clip (A) of the turbocharger delivery hose at the throttle body and the turbocharger delivery pipe's bolt (B) to the fan cowling.
|
27. |
Raise the car.
|
28. |
Fit the turbocharger delivery pipe's bolt (B) and fit the hose clip (A).
|
29. |
Aut:
Fit the lower coolant pipe to the automatic transmission.
|
30. |
Lower the car.
|
31. |
Fit
Upper radiator member, Z19DTR
|
32. |
Pressure test the cooling system, see
Cooling system, pressure testing
.
|
33. |
Fill with coolant, see
Filling and bleeding the cooling system, Z19
.
|
34. |
Fit the insulation and the upper engine cover.
|
35. |
Check/adjust the oil level.
|