Withdrawal
Remove the hood. Open cap -arrow- of expansion tank. Remove noise insulation -arrows-. Remove the front bumper panel. Place a pallet for service cranes -VAS 6208- under the engine. Detach lower coolant hose -arrow- from radiator and drain off coolant. Pos. -1- ignore.
Detach lower air hose from intercooler -arrow-.
Loosen bolts -1 and 4- of lower radiator mounting on fan frame.
Vehicles with AMF, BHC engines
Unplug electrical connector -1- for intake manifold pressure sender -G71- and unfasten electrical cable.
All
Detach air hose -2- from intercooler.
Remove upper left coolant hose from radiator Pos. -2-.
Pos. -1- ignore. Loosen bolts -2 and 3- of upper radiator mounting on fan frame. Disconnect the horn connector. Unscrew 2 bolts -3- left and right each and remove reinforcement bar. Raise lock washers -2-. Unscrew left and right bolts -1- and remove bumper safety bar.
Unplug electrical connector -1- for high pressure sender -G65-. Cut cable tie -2-.
Remove temperature sensor -fresh air -G17- -arrow- from bracket.
Press out wiring harness to high pressure sender -G65- and outside temperature sender -G17- on left air duct, to do this use lever -80.200-.
Unscrew air ducts from radiator bracket -arrows-. Do not open the air conditioning circuit of the air conditioner.
Remove bolts for condenser -arrows-.
Instruction. To avoid damage to the refrigerant lines and hoses, when handling the condenser, make sure that the lines and hoses are laid without tension, kinks or kinks.
Turn condenser slightly forward towards right side of vehicle -arrow 1-. Move radiator with intercooler as far as possible towards left side of vehicle -arrow 2-.
Lubricate the rubber bushings of the intercooler suspension with a silicone-free lubricant. Remove the intercooler fixing lugs from the rubber bushings in the radiator frame. To do this, move the lugs of the radiator frame a little to the right -arrow 3-. Carefully push the condenser with intercooler forward along the connecting side (left) to the maximum possible distance. Remove the radiator connections one by one from the fan frame while turning the radiator up or down. Remove the radiator with intercooler by pushing it to the left.
Remove all 4 bolts connecting intercooler to radiator -arrows-.
Installation
Installation, in reverse order, while installing the safety bar and reinforcement bar, install the front bumper panel, install the air ducts in the clips. Fill up the coolant.
Tightening torques:
- Intercooler to radiator: 6 Nm
- Radiator to fan frame: 6 Nm
- Capacitor to fan frame: 6 Nm
- Air ducts to fan frame: 1.5 Nm
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