Removal And Installation: Radiator

Special tools and workshop equipment required

Drip Tray for VAS 6100 VAS 6208

Removing

Fig 1: Coolant Level Markings

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NOTE:

If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS .

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

-- Open the coolant reservoir cap.

-- Remove the charge air cooler. Refer to CHARGE AIR COOLER .

-- Remove the noise insulation frame -arrow- with the rear noise insulation. Refer to Removal and Installation .

Fig 2: Identifying Noise Insulation Frame

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-- Remove the fan shroud. Refer to FAN SHROUD .

-- Place the VAS 6208 under engine.

Fig 3: Identifying Coolant Hose Quick Acting Coupling

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-- Open the clamp, drain the coolant and then remove the lower coolant hose -arrow- from the radiator.

-- Remove nuts -1- and push the coolant pipe toward the rear.

Fig 4: Identifying Nuts & Coolant Pipe

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NOTE:

Ignore -2-.

-- Disconnect the coolant hose from the radiator by raising the retaining clip -arrow-.

Fig 5: Identifying Upper Coolant Hose & Retaining Clip -Arrow-

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-- Remove the bolts -arrows-.

Fig 6: Air Cooler Lower Mounting Bolts

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-- Tip radiator back slightly at upper edge.

-- Disengage radiator from lower mounting points by raising radiator.

-- Slide radiator in direction of engine.

-- To prevent radiator from sinking down, support it from below.

Fig 7: Charge Air Cooler Bolts

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WARNING:

Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

CAUTION:

Risk of damage to condenser and refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the bolts -arrows-.

-- Remove condenser from radiator.

-- Place condenser forward in lock carrier and secure against falling down with cable ties.

-- Remove radiator downward.

Installing

Install in reverse order, paying attention to the following:

For the correct tightening specifications, refer to RADIATOR AND COOLANT FAN OVERVIEW .

-- Install condenser. Refer to Removal and Installation .

-- Install fan shroud. Refer to FAN SHROUD .

-- Connect the coolant hose to the connector on the radiator. Refer to Figure.

-- Install the noise insulation frame. Refer to Removal and Installation .

-- Install the charge air cooler. Refer to CHARGE AIR COOLER .

-- Fill the engine with coolant. Refer to COOLANT, DRAINING AND FILLING .