Radiator: Service and Repair
Radiator/charge air cooler (CAC), replacing
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Removal
Preparatory work
Drain the A/C system, using appropriate procedures.
Removing the engine cooling fan (FC)
Remove:
- the engine cooling fan (FC). See Engine cooling fan (FC), replacing Service and Repair
- the screws for the air conditioning aggregate on the front cover plate
- the expansion tank cap.
Removing the front bumper cover
Remove the front bumper cover. Service and Repair
Removing the air conditioning aggregate
Remove:
- the air baffle
- the lower oil cooler hose from the air conditioning aggregate (automatics transmissions only).
Note! Collect the oil from the oil cooler in a container.
Remove the screw for the mounting for the cable duct for engine wiring at the front edge of the sub-frame.
Draining coolant
Block the lower hose using lock grip pliers.
Install a hose on the nipple at the radiator.
Feed the hose down to a container.
Open the nipple and drain off the coolant.
Remove:
- the hose for the additional charge air cooler (CAC) on the left-hand side
- the lower radiator hose.
Removing the radiator assembly, continued
Remove from the right-hand side:
- the upper radiator hose. Block the upper radiator hose with lock grip pliers. Put to one side
- the charge air hose.
Remove from the left-hand side:
- the hose from the air conditioning aggregate to the expansion tank (1)
- the upper oil cooler hose (2) (automatics only)
- the charge air pipe (3).
Disconnect and hang the pipe for the condenser to the side on the left-hand side.
Note! Plug the pipes and the condenser to prevent moisture build-up in the system.
Disconnect the pipe for the dryer bottle. Hang the pipe to one side on the right-hand side.
Note! Plug the pipes and the dryer to prevent moisture build-up in the system.
Apply a transmission jack under the air conditioning aggregate. Slacken off the two screws.
Carefully lower approximately 20 cm. Disconnect the connector for the dryer bottle.
Lower the radiator assembly fully.
Note! Hold the air conditioning aggregate so that it does not fall while lowering. Ensure that no cable harnesses or hoses are trapped when lowering the air conditioning aggregate.
Removing the radiator and the charge air cooler (CAC)
Remove the hose for the additional charge air cooler (CAC).
Remove:
- the four screws
- radiator
- the charge air cooler (CAC).
Installation
Note! For tightening torques, see Tightening torque Tightening Torque.
Installing the radiator and the charge air cooler (CAC)
Install:
- the charge air cooler (CAC)
- radiator
- the 4 M6 screws
- the hose for the additional charge air cooler (CAC).
Installing the cooler unit
Place the air conditioning aggregate on the transmission jack and raise it carefully.
Note! Ensure that no cable harnesses or hoses are trapped.
Raise until it is approximately 20 cm from the installed position. Connect the connector to the dryer.
Raise fully and install the 2 M8 screws.
Right-hand side:
Install the pipe on the dryer bottle using an M6 screw. Use a new O-ring.
Left side:
Install the pipe on the condenser using an M8 screw. Use a new O-ring.
Install:
- the hose on the additional charge air cooler (CAC)
- the lower radiator hose
- the lower oil cooler hose (automatics only).
Installing the radiator assembly, continued
Install on the right-hand side:
- the charge air hose
- the upper radiator hose.
Install on the left-hand side:
- the charge air pipe
- the upper oil cooler hose (automatics only)
- the hose from the expansion tank on the radiator.
Installing the cooler unit
Install:
- the air baffle
- the air hose between the air cleaner (ACL) housing and the front cover plate
- the air cleaner (ACL) housing.
Installing the front bumper cover
Install the front bumper cover. See Bumper front, replacing Service and Repair (-2004) or Bumper front, replacing Service and Repair (2005-).
Installing the engine cooling fan (FC)
Install:
- the engine cooling fan (FC). See Engine cooling fan (FC), replacing Service and Repair
- the 2 M6 screws for the air conditioning aggregate on the front cover plate.
Finishing
Fill with coolant and run the engine until the thermostat opens. Top up as necessary.
Check the transmission oil level (automatic transmissions only). Top up if necessary.
Filling with refrigerant
Lower the car.
Vacuum pump. See Vacuum pumping Vacuum Pumping.
Fill the A/C system. See Refrigerant, filling Refrigerant, Filling.
Check for leaks. See Leak tracing, fluorescent tracing agent / UV lamp Leak Tracing, Fluorescent Tracing Agent / UV Lamp or Leak tracing, electronic leak tracer Leak Tracing, Electronic Leak Tracer.