Contents: Removal ⤓ Installation ⤓
After a long mileage of the car, the thin channels of the radiator become clogged with particles that have entered the coolant and lime deposits. Because of this, the cooling capacity is sharply reduced, and the engine overheats. In this case, only replacing the radiator can help. The designations in the text refer to Figure K-1809.
Removal
Disconnect the ground cable from the battery.
Caution: This erases data in the electronic memory, such as the engine fault memory or the radio receiver code. Disconnect the battery only when the ignition is switched off, otherwise the fuel injection device control unit may be damaged. Before disconnecting the battery, read the instructions in the "Radio receiver" and "Removing and installing the battery" sections.
Drain the coolant, see p. 3.3.
Unscrew the battery holder "4".
Unscrew the windshield washer reservoir "5" and set it aside with the hoses connected.
Remove the air tube from tank "6".
Remove hose "6" from the radiator to the expansion tank, having first loosened the clamps.
Remove expansion tank "7".
Disconnect the upper "8" and lower "9" coolant hoses from the radiator, first loosening and moving the clamps back.
If available, disconnect the oil cooler hoses "10". To prevent dirt and foreign objects from entering, plug the hoses and fittings.
Remove the connector from the thermal switch on the radiator.
Remove the radiator fan connector.
Unfasten the upper rubber support and remove the radiator together with the fan.
If there are problems with free space, remove the radiator fan first.
Caution: The radiator fins have very sharp edges, so it is recommended to wear work gloves when removing the radiator.
Caution: If the radiator is to remain removed for more than 48 hours, flush it with water, blow it with compressed air and plug the holes. The radiator can also be filled with coolant and set aside with the plugs closed. Otherwise, corrosion may occur, which will subsequently lead to leaks.
Installation
If necessary, move the thermal switch and fan to the new radiator.
Check all coolant hoses for cuts, cracks and other damage and replace if necessary. Check the condition of the rubber radiator mounts.
Insert the radiator from above so that the radiator mounting pins fit into the rubber supports from below.
Place the upper support and tighten the mounting bolts.
Install the upper and lower coolant hoses and secure with clamps.
If removed, connect and secure the oil radiator hoses with clamps.
Connect the wires to the thermal switch and the fan.
Install and secure the windshield washer reservoir.
Install the battery holder.
Caution: When replacing or repositioning the drain plug, replace the sealing ring.
Fill with coolant, see p. 3.3.
Connect the ground cable to the battery.
If available, set the time on the clock and set the security code in the radio.
Warm up the engine and check the tightness of the hose and radiator connections.
Check the coolant level and top up if necessary.