Table of contents: Removal ↓ Installation ↓
Removal
Remove the hood. Open the expansion tank cap "arrow". Remove the noise insulation "arrow". Remove the front bumper panel. Place the tray for the service cranes "VAS 6208" under the engine. Remove the lower coolant supply hose "arrow" from the radiator and drain the coolant. Ignore pos. "1".
Remove the lower air duct hose from the "arrow" intercooler.
Unscrew bolts "1 and 4" of the lower radiator mount on the fan frame.
Cars with AMF, BHC engines
Disconnect plug connector "1" of intake manifold pressure sensor "G71" and loosen the electrical wire.
All
Remove the air duct hose "2" from the intercooler.
Remove the left upper coolant supply hose from the radiator, Item "2".
Ignore pos. "1". Unscrew bolts "2 and 3" of the upper radiator mount on the fan frame. Disconnect the horn connector. Unscrew 2 bolts "3" on the left and right and remove the reinforcement bar. Lift the lock washers "2". Unscrew the left and right bolts "1" and remove the bumper safety bar.
Disconnect plug connector "1" of high pressure sensor "G65". Cut cable tie "2".
Remove the outside air temperature sensor "G17" "arrow" from the bracket.
Press the electrical wiring harness to the high pressure sensor "G65" and the outside air temperature sensor "G17" of the left air duct, for this use the lever "80.200".
Unscrew the air ducts from the radiator frame "arrows". It is prohibited to open the air conditioning system circuit of the air conditioning system.
Unscrew the bolts of the "arrow" capacitor.
Instructions: To avoid damage to the refrigerant supply lines and hoses, when handling the condenser, ensure that the lines and hoses are laid without tension, kinks, or breaks.
Turn the condenser slightly forward towards the right side of the car "arrow 1". Move the radiator with the intercooler as far as possible towards the left side of the car "arrow 2".
Lubricate the rubber bushings of the intercooler mount with silicone-free grease. Remove the intercooler mounting tabs from the rubber bushings in the radiator frame; to do this, move the radiator frame lugs slightly to the right "arrow 3". Carefully push the condenser with the intercooler forward along the connecting side (left) to the maximum possible distance. Pull the radiator connections out of the fan frame one by one, while turning the radiator up or down. Remove the radiator with the intercooler, pushing it to the left.
Unscrew all 4 bolts connecting the intercooler to the "arrow" radiator.
Installation
Installation, in reverse order, it is necessary to install the safety bar and the reinforcement bar, Install the front bumper panel, install the air ducts in the clamps. Fill with 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