197019 Removing and installing radiator

WM 197019 Removing and installing radiator

Technical values

Preliminary work

DANGER

Vehicle can fall down

- Risk of squashing or crushing
- Risk of damage to the vehicle

-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.

Information

The air-conditioning condenser remains in the vehicle. The air-conditioning system must not be opened.

1. Remove front wheel housing liner. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair.
2. Remove the front apron. -> 631519 Removing and installing front apron - "Removing" section .
3. Drain coolant. -> 193817 Draining and filling coolant - section on "Draining" Service and Repair.
4. Remove air guides from the radiators. -> 192419 Removing and installing air guide - section on "Removing" Service and Repair.
5. Release air-conditioning condenser from side radiator.
-> 87501900 Removing and installing condenser Service and Repair.
5.1. Unscrew sheet metal screw between air-conditioning condenser and side radiator.
5.2. Pull air-conditioning condenser out of side brackets.

Removing radiator

Removing left radiator

WARNING

Hot fluid

- Danger of scalding

-> Let the fluid cool down.
-> Wear personal protective gear.

WARNING

Caustic fluids

- Danger of chemical burns

-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

1. Remove the transverse strut -1-.
1.1. Turn out the hex nuts (SW 10) M6 -2- and remove the transverse strut -1-.

Transverse strut, left

2. Unlock and remove cable plug from fan motor -arrow-.

Cable plug

3. Pull off coolant hoses.
3.1. Remove spring clamps -arrows- on the Henn couplings. Do not overstretch the spring clamps.
3.2. Remove coolant hoses -1- and reinstall the spring clamps -arrow-.

Coolant hoses, radiator

4. Remove left radiator module.

Left radiator module

4.1. Unscrew the two fastening nuts (M8) -1-.
4.2. Remove the plug-in coupling -2- by pressing the locking tabs and pulling off the vent line.
4.3. Release hose holder. Unscrew outer torx screw (E10) M6 x 16 -arrow- at hose holder.

Hose holder fiting

4.4. Unscrew two hex screws (SW 13) M8 x 25 -3-.
4.5. Remove left radiator -4- module.

Information

- Despite the fact that the coolant has been drained, residual amounts of coolant can still emerge at the joints during removal.

- Have sufficient collecting containers and cloths to hand.

- Do not overstretch spring clamps on the Henn couplings.

5. Remove radiator fan housing.
5.1. Disconnect the two coolant hoses from the supports for the radiator.

Radiator connections

5.1.1. Release the spring band clamps -arrows- and pull off the coolant hoses from the support.
5.2. Unclip -arrows- sheet metal clips.

Bracket for side radiator

5.3. Remove radiator fan housing.

Cooling fan

5.3.1. Unscrew two hex screws (SW 8) -1-.
5.3.2. Remove radiator fan housing with rear air guide from the tabs of the side radiator -2-.

Removing right radiator

WARNING

Hot fluid

- Danger of scalding

-> Let the fluid cool down.
-> Wear personal protective gear.

WARNING

Caustic fluids

- Danger of chemical burns

-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Information

- Despite the fact that the coolant has been drained, residual amounts of coolant can still emerge at the joints during removal.

- Have sufficient collecting containers and cloths to hand.

- Do not overstretch spring clamps on the Henn couplings.

1. Remove transverse strut.

Transverse strut for wheel housing

1.1. Turn out the hex nuts (SW 10) M6 -2- and remove the transverse strut -1-.
2. Remove control unit and unlock connector from the electric fan and pull it off.

Control unit at wheel housing

2.1. Unscrew M6 x 25 outer Torx screw (E10) -2-.
2.2. Position the control unit -1- with holder.
2.3. Release and disconnect cable plug for fan motor -3-.
3. Pull off coolant hoses.
3.1. Remove spring clamps -arrows- on the Henn couplings and pull off coolant hoses -1-.
3.2. Make sure that the spring clamps -arrows- are not overstretched.

Coolant hoses, radiator

4. Remove right radiator module.
4.1. Unscrew two collar nuts (SW 13) -1-.
4.2. Connect the plug-in coupling -2- by pressing the locking tabs and pulling off the vent line.
4.3. Release hose holder. Unscrew M6 x 16 outer Torx screw (E10) -arrow-.

Hose holder fiting

4.4. Unscrew two hex screws (SW 13) M8 x 25 -3-.
4.5. Remove right radiator module.

Right radiator module

5. Remove radiator fan housing.
5.1. Disconnect the two coolant hoses from the supports for the radiator.

Radiator connections

5.1.1. Release the spring band clamps -arrows- and pull off the coolant hoses from the support.
5.2. Unclip -arrows- sheet metal clips.

Bracket for side radiator

5.3. Remove radiator fan housing.

Cooling fan

5.3.1. Unscrew two hex screws (SW 8) -1-.
5.3.2. Remove radiator fan housing with rear air guide from the tabs of the side radiator -2-.

Installation

Installing left radiator

Installation position

1. Fit radiator fan housing.
1.1. Insert and secure the cooling fan housing.

Cooling fan

1.1.1. Insert radiator fan housing with rear air guide into the tabs of the side radiator -2-.
1.1.2. Screw in and tighten two hex screws (SW 8) -1-.
1.2. Clip in sheetmetal clips.

Bracket for side radiator

1.2.1. Push radiator module into the radiator bracket.
Make sure that the radiator is positioned correctly in the side guide and in the lower bores.
1.2.2. Fit washers and sheetmetal clips on the lower fastening pins of the radiator in such a way that the sheetmetal clips engage correctly into the pins -arrows-.
1.3. Connect both coolant hoses to the connection pieces on the radiator.

Radiator connections

Push the coolant hoses onto the supports and secure with the spring-band clamps -arrows-.
1.4. Secure the hose holder.

Hose holder fiting

Screw in and tighten outer torx screw (E10) M6 x 16 -arrow- at hose holder. => Tightening torque: 10 Nm
2. Install left radiator module.

Left radiator module

2.1. Insert left radiator module -4- and screw in and tighten two hex screws (SW 13) M8 x 25 -3-. => Tightening torque: 23 Nm
2.2. Plug vent line -2- onto supports of radiator module.
2.3. Screw in and tighten the two collar nuts (M8) -1-.
=> Tightening torque: 23 Nm
3. Connect cable connector -arrow- of radiator module.

Cable plug

4. Connect coolant hoses.

Coolant hoses for radiator

4.1. Plug coolant hoses -1- onto coolant supports
4.2. Secure spring clamps -arrows- on the Henn couplings.
Make sure that the Henn plug engages audibly.
5. Install the transverse strut.

Transverse strut for wheel housing

Insert transverse strut -1- then screw in and tighten hex nuts (SW 10) M6 -2-.
=> Tightening torque: 10 ftlb.

Installing right radiator

1. fit radiator fan housing.
1.1. Insert and secure the cooling fan housing.

Cooling fan

1.1.1. Insert radiator fan housing with rear air guide into the tabs of the side radiator -2-.
1.1.2. Place on and tighten two hex screws (SW 8) -1-.
1.2. fit sheet metal clips.

Bracket for side radiator

1.2.1. Push radiator module into the radiator bracket.
Make sure that the radiator is positioned correctly in the side guide and in the lower bores.
1.2.2. Fit washers and sheetmetal clips on the lower fastening pins of the radiator in such a way that the sheetmetal clips engage correctly into the pins -arrows-.
1.3. Fit both coolant hoses on the supports for the radiator.

Radiator connections

1.3.1. Push coolant hoses onto the supports.
1.3.2. Fit spring band clamps -arrows-.
1.4. Secure the hose holder.

Hose holder fiting

1.4.1. Place on and tighten outer torx screw M6 x 16 -arrow- at hose holder. => Tightening torque: 10 Nm
2. Install right radiator module.

Right radiator module

2.1. Insert left radiator module.

2.1.1. Place on and tighten two hex screws (SW 13) M8 x 25 -3-. => Tightening torque: 23 Nm
2.2. Plug vent line -2- onto supports of radiator module.
2.3. Place on and tighten the two collar nuts (M8) -1-. => Tightening torque: 23 Nm
3. Fit control unit and connect electric fan.

Control unit at wheel housing

3.1. Position the control unit -1- with holder.
3.2. Fit and tighten M6 x 16 outer Torx screw (E10) -2-. => Tightening torque: 10 Nm
3.3. Fit cable connector -3- of radiator module.
4. Fit coolant hoses.

Transverse strut for wheel housing

5.1. Insert transverse strut -1-.
5.2. Place on hex screw (SW 10) M6 -2- and tighten. => Tightening torque: 10 ftlb.

Subsequent work

1. Install air-conditioning condenser on side radiator.
-> 87501900 Removing and installing condenser Service and Repair.
1.1. Push air-conditioning condenser into side bracket.
1.2. Place sheet metal screw of air-conditioning condenser on side radiator and tighten it.
2. Install air guides in front of side radiator. -> 192419 Removing and installing air guide - section on "Installing" Service and Repair.
3. Install front apron. -> 631519 Removing and installing front apron - "Installing" section .
4. Install wheel housing liner. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.
5. Fill in coolant and bleed cooling system. -> 193817 Draining and filling coolant - section on "Filling" Service and Repair.