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Radiator, Z19DTR

Radiator, Z19DTR

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 (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.

Important

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


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.

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.


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.