Radiator: Service and Repair

LEGEND
1 Bolt
2 Cover
3 Lock Carrier
4 Air Intake Elbow
5 Bracket
6 Radiator
7 Rubber Washer
8 V-belt
9 Expandable Pin
10 Guide Shroud
11 Additional Fan
12 Fan Ring
13 Connector
14 Radiator Fan
15 Radiator Fan
16 To Coolant Pipe
17 Cap
18 To Expansion Tank Connection
19 Lower Coolant Hose
20 Connection
21 O-ring
22 Retaining Clip
23 Upper Coolant Hose
24 Coolant Fan Control Thermal Switch

NOTE: During removal and installation procedures, refer to the component location illustration above and component notes below.

COMPONENT NOTES
Bolt (1)
- Tighten to: 10 Nm (7 ft. lbs.).

Radiator (6)
- After replacing, completely replace engine coolant.

Guide Shroud (10)
- Note fitting position.
- Secured on lock carrier (item 3) with clips.

Cap (17)
- Test Pressure 1.3-1.5 bar (18.85-21.75).

Lower Coolant Hose (19)
- To water pump.

O-ring (21)
- Always replace.

Coolant Fan Control Thermal Switch (F18) (24)
- Tighten to: 35 Nm (26 ft. lbs.).
- Switching temperatures:

- Stage 1
On: 92-97°C (198-207°F)
Off: 84-105°C (183-196°F)

- Stage 2:
On: 99-105°C (210-221°F)
Off: 91-98°C (196-208°F)

- A three speed coolant fan control is used only with optional extra equipment, refer to Radiator Hose.

SPECIAL TOOLS
^ Pliers for spring type coolant hose clips tool No. VAG 1921, or equivalent.

REMOVAL
1. Drain coolant. Service and Repair
2. Remove radiator coolant hoses
3. Pull connectors off thermoswitch and radiator fan
4. Remove radiator mounting bolt
5. Remove lock carrier with attachments, refer to Body and Frame. Service and Repair
6. Lift out radiator, fan and air guide housing.

NOTE:
- Vehicles with A/C, observe the following additional information:
- Do NOT open the A/C refrigerant circuit.
- To prevent damage to the condenser and refrigerant lines/hoses, ensure that they are not stretched, kinked or bent.

a. Remove Air Cleaner assembly.
b. Remove A/C fluid reservoir and allow to hang free.
c. Remove retaining clamp(s) from refrigerant lines.
d. Remove condenser from radiator and pull forward as far as possible.
e. Lift out radiator and fan assembly.
f. Secure condenser to body so that refrigerant lines/hoses are not stressed.

INSTALLING
Installation is carried out in the reverse order of the removal procedure noting the following:
- Filling with coolant. Service and Repair
- Electrical connections and routing.
- Check headlight alignment and adjust if necessary.