Contents: Removal ⬇ Installation ⬇
Note: On vehicles from year 04 with ESP - after each battery disconnection the steering wheel angle sensor loses its basic setting. It must be recalibrated.
Removal
Disconnect the battery terminals.
Disconnect the ground wire.
Drain the coolant.
Place a receiving tray underneath.
Open the drain plug (arrow).
Release the front trim at the top.
Remove 3 mounting bolts 1.
Raise the car.
Release the front trim at the bottom.
Release 3 clamps 2.
Unscrew the 4 mounting bolts 1.
Unscrew 2 nuts 3.
Remove the front trim.
Disconnect the temperature sensor wiring harness connector.
Lower the car.
Disconnect the clamp from the fan housing (arrow).
Remove by pulling down.
Remove the horn.
Disconnect the wiring harness connector.
Remove the bolt.
Lower the car.
Drain the coolant.
Place a receiving tray underneath.
Open the drain plug (arrow).
Remove the suction pipe 1.
Remove the oil dipstick.
Remove bolt 2.
Remove the bypass hose from the radiator.
Remove the radiator hose at the top.
Release 2 clamps.
Remove the radiator hose at the bottom.
Release the clamp.
Disconnect the radiator hose from the fan housing and the hydraulic unit holder.
Remove the fan housing.
Disconnect the 2 wire harness connectors.
Auxiliary fan motor, pneumatic switch.
Unscrew 2 mounting bolts 1.
Carefully pull the fan housing upwards and place it on the engine.
Release the refrigeration condenser.
Note: The air conditioning system remains closed.
Unscrew the 2 mounting bolts (arrows).
Remove the capacitor from the holder.
Hang the capacitor.
Remove the radiator.
Remove the 2 radiator holders at the bottom.
Unscrew the 4 mounting bolts.
Carefully remove the radiator by pulling it downwards.
Installation
Install the radiator.
Close the threaded plug of the coolant drain port.
Insert the radiator.
Install 2 radiator holders at the bottom.
Tighten the 4 mounting bolts to 25 Nm.
Secure the refrigeration condenser.
Unhook the capacitor.
Insert into the holder.
Tighten the 2 mounting bolts to 5 Nm.
Install the fan housing.
Carefully place the fan housing on.
Tighten the 2 mounting bolts to 5 Nm.
Connect the wire harness connector.
Install the radiator hose at the bottom.
Secure the clamp.
Secure the hose.
Install the radiator hose at the top.
Secure 2 clamps.
Install the bypass hose.
Install the suction pipe.
Insert into the front from above.
Tighten the bolt.
Insert the oil dipstick.
Raise the car.
Set the sound signal.
Tighten the bolt.
Connect the wire harness connector.
Install the mounting clamp.
Install the front trim.
Connect the wire harness connector.
Secure the front trim at the bottom.
Install 3 clamps.
Tighten the 4 mounting bolts.
Tighten 2 nuts.
Lower the car
Secure the front trim at the top.
Tighten the 3 mounting bolts.
Connect the battery terminals.
Fill the cooling system and bleed air from it.
Program volatile memory.
Close the hood.
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