Radiator: Service and Repair
WM 197019 Removing and installing radiator
Preliminary work
1. Drain coolant.
-> 193817 Draining and filling in coolant Service and Repair
2. Drain refrigerant from air conditioning.
-> 870317 Draining and filling in refrigerant Service and Repair
3. Remove radiator fan housing.
-> 192019 Removing and installing cooling fan housing (radiator frame) 192019 Removing and installing cooling fan housing (radiator frame)
4. Remove front apron.
-> 631519 Removing and installing front apron
5. Remove lock carrier.
-> 503819 Removing and installing lock carrier 503819 Removing and Installing Lock Carrier
Removing radiator
WARNING
ATF!
- Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
-> Before lines are opened, place a cloth underneath them!
-> Components that come into contact with ATF must be cleaned IMMEDIATELY with water!
-> Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)
-> Collect emerging ATF!
CAUTION
Hot components
- Risk of burns
-> Let hot components cool down.
-> Wear personal protective gear.
NOTICE
Aggressive fluids
- Risk of damage to components and surfaces
-> Do not spill fluids.
-> If a component comes into contact with the fluid, wash the component or surface with water.
-> Replace components that are already damaged.
NOTICE
Opened refrigerant system for repairs.
- Moisture penetrated into the refrigerant system.
- Soiling of refrigerant circuit.
- Saturation and subsequent disintegration of dryer.
- If the dryer has disintegrated, the dryer, compressor and evaporator may be damaged.
-> If the air humidity is too high and if the refrigerant circuit is open for some time, it will be necessary to replace the dryer.
Information
- These instructions describe how to remove and install the engine on vehicles with turbo engines with the maximum number of accessories and components.
- Some of the steps described here may not be necessary on vehicles with naturally aspirated engines or on 2WD vehicles, for example, since these vehicles do not have certain accessories and components.
- The slightly different illustrations between the naturally aspirated engine and the turbo engine show essentially the same tasks.
1. Remove fastening screws for air conditioning lines at the air conditioning condenser, disconnect air conditioning lines and place to the rear => Air conditioning lines.
Information
After disconnecting hoses, close off all openings immediately using commercially available rubber stoppers.
When fitting parts, do not remove stoppers until shortly before installation. Likewise, do not remove the protective foil from the dryer until just before installation. The dryer absorbs moisture from the air and is then useless.
Information
- Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.
Air conditioning lines
2. Remove centre air guide in front of the radiator.
2.1. Remove the two plastic expansion rivets -arrows- using a screwdriver.
Plastic expansion rivets for air guide
2.2. Loosen the locking lugs -arrow- for the air guide on both sides and remove the air guide.
Locking lug for air guide
3. Remove condenser.
3.1. Remove the fastening screws on both sides -arrows- for the cover.
Fastening screws for condenser cover
3.2. Push the cover upwards out of the guide and remove => Guide for condenser cover.
Guide for condenser cover
3.3. Push the condenser upwards out of the guide and remove => Removing condenser.
Removing condenser
4. Remove holder for the lines at the radiator.
4.1. Unclip the holder for the servo lines on the left and remove them => Servo line holder.
Servo line holder
4.2. Unscrew the fastening screw for the transmission oil line holder on the right and remove holder => Transmission oil line holder.
Transmission oil line holder
5. Detach condenser retaining frame.
Condenser retaining frame
5.1. Unscrew the fastening screws on both sides -A and B-.
5.2. Push retaining frame down and out of the guide on both sides -C-.
6. Remove radiator mounting out of guide => Radiator mounting.
Radiator mounting
7. Remove accessories from radiator.
Hose connection
7.1. Detach supply hose or return hose -A- from the radiator on both sides.
7.2. Release the temperature sensor connector -B- on the left and disconnect it.
7.3. Release the vent line on the left on the radiator -A- and disconnect it -B-.
Vent line connector
8. Swivel radiator forwards and remove it upwards => Removing radiator.
Removing radiator
Installing radiator
1. Insert radiator and swivel it to the rear => Inserting radiator.
Inserting radiator
2. Fit accessories on the radiator.
Hose connection
2.1. Fit supply hose or return hose on both sides -A- onto the radiator.
2.2. Insert the temperature sensor connector -B- on the left.
2.3. Insert the vent line on the left on the radiator -B- and make sure that the locking mechanism -A- latches in.
Vent line connector
3. Insert radiator mounting into the receptacles provided => Radiator mounting.
Radiator mounting
4. Fit condenser retaining frame.
Condenser retaining frame
4.1. Push retaining frame up into the guide on both sides -C-.
4.2. Fit the fastening screws on both sides -A and B-.
5. Fit holder for the lines at the radiator.
5.1. Fit the holder for the servo lines on the left => Servo line holder.
Servo line holder
5.2. Fit the fastening screw for the transmission oil line holder on the right => Transmission oil line holder.
Transmission oil line holder
6. Install condenser.
6.1. Push the condenser down into the guide => Inserting condenser.
Inserting condenser
6.2. Push the cover down into the guide => Guide for condenser cover.
Guide for condenser cover
6.3. Fit the fastening screws on both sides -arrows- for the cover.
Fastening screws for condenser cover
7. Fit centre air guide.
7.1. Insert the air guide into the locking lugs on both sides -arrow-.
Locking lug for air guide
7.2. Fit the two plastic expansion rivets -arrows- using a screwdriver.
Plastic expansion rivets for air guide
8. Position air conditioning line and install fastening screws -arrows-.
For tightening torques refer to: -> 875019 Removing and installing condenser Service and Repair
Air conditioning lines
Subsequent work
1. Install radiator fan housing.
-> 192019 Removing and installing cooling fan housing (radiator frame) 192019 Removing and installing cooling fan housing (radiator frame)
2. Install lock carrier.
-> 503819 Removing and installing lock carrier 503819 Removing and Installing Lock Carrier
3. Install front apron.
-> 631519 Removing and installing front apron
4. Fill in coolant.
-> 193817 Draining and filling in coolant Service and Repair
5. Filling in refrigerant for the air conditioning.
-> 870317 Draining and filling in refrigerant Service and Repair