Removing Radiator
- Danger of chemical burns
→ Wear personal protective gear.
→ Ensure that there is good ventilation.
→ Avoid contact with caustic fluid.
→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
- Possible danger of injury or damage (e.g. 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 appropriate protective measures (protective clothing, safety goggles, oil binding material)
→ Collect emerging ATF!
- Risk of burns
→ Let hot components cool down.
→ Wear personal protective gear.
NOTIFICATION
Aggressive fluids
- Risk of damage to components and surfaces
→ Do not spill fluids.
→ In the event of contact, wash the component or surface with water.
→ Replace components that are already damaged.
NOTIFICATION
Opened refrigerant system for repairs.
- Moisture penetrated into the refrigerant system.
- Risk of contaminating the refrigerant circuit.
- Risk of saturation and irreparable damage to desiccator.
- Irreparable damage to the desiccator can damage the compressor and evaporator.
→ The desiccator must be replaced if the air humidity is high and if the refrigerant circuit is left open for a long time.
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.
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.
- Remove fastening screws -1 and 2-
for air-conditioning lines at the air-conditioning condenser, pull off air-conditioning lines and move them to the rear.
Loosening fastening screws for refrigerant lines
- Remove condenser.
Remove the fastening screws -1- for the cover at both sides.
Fastening screws on upper air guide
Push the cover up out of the guide and remove it > Removing upper air guide.
Removing upper air guide
Slide the condenser up out of the guide and remove it > Removing condenser.
Removing condenser
Removing condenser
- Remove holder for the lines at the radiator.
Unclip the holder for the power-steering lines on the left side and remove it > Holder for power-steering lines.
Holder for power-steering lines
Loosen the fastening screw for the transmission oil line holder on the right side and remove holder > Holder for transmission oil lines.
Holder for transmission oil lines
- Detach condenser retaining frame.
Condenser retaining frame
Loosen the fastening screws -A and B- on both sides.
Push the retaining frame down out of the guide on both sides -C- .
- Take the radiator mounting out of the guide > Radiator mounting.
Radiator mounting
- Remove accessories from radiator.
Hose connection for distributor tube (return line)
Disconnect supply hose and return hose -A- from the radiator on both sides.
Release the vent line on the radiator at the left side -A- and disconnect it -B- .
Vent line connector
- Swivel the radiator forward and lift it up and out. > Removing radiator
Removing radiator