Radiator, Remove and Install the Operation Is Described for a Vehicle with Air Conditioning. for Vehicles Without Air Conditioning, Proceed Analogously.
Remove coolant drain bolt (1) (accessible from underside of vehicle) from coolant pump - collect escaping coolant.
Install coolant drain bolt in coolant pump - tightening torque 20 Nm / 15 lbf. ft.
Disconnect ground cable (2) from battery and positive cable (1) from positive terminal.
Detach fuse box /relay box (3) from battery support.
Disconnect wiring harness plug (10) from intake air temperature sensor.
Detach engine vent hose (4) from cylinder head cover.
Detach vacuum line (5) of fuel pressure regulator for air intake pipe from air intake pipe.
Unclip vacuum line (7) from air intake pipe.
Release hose clamps (6) and (9) and detach air intake pipe from throttle body and from upper part of air cleaner housing.
Remove upper coolant hose (8) from radiator - collect escaping coolant.
Disconnect wiring harness plug (1) of auxiliary fan and place cable out of way.
Detach multiple plug (2) (twist lock) and disconnect ground cable (3) from body.
Detach wiring harness plug from compressor.
Unclip refrigerant line and fluid return line for power steering pump out of fan housing. Remove both line brackets from fan housing by turning 1/4 to the left (anti-clockwise).
Remove radiator grille and front panelling - see operation "Front Panelling, Remove and Install" in group "A".
Detach wiring harness plug (1) from AC pressure switch.
For version with automatic transmission: Lever off retaining clips (arrows) from quick fittings using suitable screwdriver and detach fluid cooling lines - collect escaping transmission fluid.
Remove both fastening bolts (2) and remove fan housing together with fan motor upwards.
Remove compensation tank coolant hose (1) and lower coolant hose (3) from radiator - collect escaping coolant.
Remove fastening bolt for refrigerant line block connection (4).
Detach left retaining bracket (2) and right retaining bracket from front air deflector panel.
Remove right headlamp - see corresponding operation in group "N".
Remove fastening bolts (arrows) and carefully remove air intake pipe (5) forwards.
Attach auxiliary fan housing together with condenser to air deflector panel.
Remove fastening bolts (1) and (2) and carefully remove radiator upwards.
For version with automatic transmission and replacement of radiator: Transfer automatic transmission fluid cooler lines with new seal rings.
Carefully insert radiator into lower brackets and attach auxiliary fan housing together with condenser to radiator.
Carefully insert air duct pipe and attach using the fastening bolts.
Install front right headlamp - see corresponding operation in group "N".
Attach refrigerant line block connection to radiator using the fastening bolt.
Attach lower coolant hose and compensation tank coolant hose to radiator.
Secure radiator to air deflector panel with right and left retaining brackets.
Insert fan housing together with cable bundle from above and attach to radiator using the two fastening bolts.
Attach upper coolant hose to radiator.
Install front panelling and radiator grille - see operation "Front Panelling, Remove and Install" in group "A".
For version with automatic transmission: Connect oil cooler lines and fasten with retaining clips.
Attach refrigerant line bracket / bracket for fluid return line of power steering pump to fan housing. Clip fluid return line and refrigerant line into bracket.
Connect wiring harness plug to AC pressure switch and to compressor.
Connect wiring harness plug for auxiliary fan and secure cable with cable tie to fan housing.
Attach ground cable to body, connect multiplug (twist lock) and lock.
Attach fuse box/ relay box to battery support.
Attach positive cable to positive terminal and connect ground cable to battery.
It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.
Attach air intake pipe to throttle body and to upper part of air cleaner housing - secure hose clamps.
Clip vacuum line into air intake pipe.
Connect hose of fuel pressure regulator for air intake pipe to air intake pipe.
Attach engine vent hose to cylinder head cover.
Connect wiring harness plug to intake air temperature sensor.
Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".
Check transmission fluid level - see operation "Transmission Fluid, Top up and Correct" in group "K".