Mercedes-Benz Parts Catalog Mercedes-Benz Accessories Catalog Mercedes-Benz Technical Articles Mercedes-Benz Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Radiator Replacement

Steve Vernon

Time:

4 hours4 hrs

Tab:

$300 to $600

Talent:

**

Tools:

25mm wrench, flathead screw driver, pliers

Applicable Models:

C350 (2007-14)
SLK350 (2004-14)
CLS350 (2004-14)
CLK350 (2005-14)
E350 (2005-14)
S350 (2005-14)
SL350 (2005-14)
R350 (2006-14)
ML350 (2006-14)
Viano (2005-14)
Sprinter (2006-14)
CLC350 (2008-14)
GLK350 (2008-12)

Parts Required:

Radiator, coolant, transmission fluid

Hot Tip:

Work on a cool car

Performance Gain:

Proper operating temperature

Complementary Modification:

New hoses

The radiators on the Mercedes-Benz W204 have been made out of both plastic and metal for several years now. Like any other car they can wear out with time and age. They are also much more susceptible to breaking at the fitting. Unfortunately, if a fitting breaks you need to replace the entire radiator. The unit itself is expensive to replace, so before you buy a new one, pressure test the cooling system first and verify the location of any leaks. It will be easier and cheaper to replace a radiator hose or clamp than replacing the whole radiator.

The radiator on the W204 is not that difficult to replace. There is just a fair amount of stuff that you need to move out of the way to do it. If you take your time and begin by working on a cool car you will be fine.

You need to remove the front engine cover (red arrow) and the air ducts (yellow arrows) to replace the coolant hoses so please see our article on engine cover removal for additional assistance.
Figure 1

You need to remove the front engine cover (red arrow) and the air ducts (yellow arrows) to replace the coolant hoses so please see our article on engine cover removal for additional assistance.

Next you need to remove the under body trays and drain the radiator (red arrow).
Figure 2

Next you need to remove the under body trays and drain the radiator (red arrow). Please see our article on these procedures for further assistance.

There are three coolant lines: the left side line that connects the radiator to the thermostat and reservoir (red arrows), the right side hose that connects the radiator to the water pump and heater core (yellow arrows) and the hose that connects the coolant reservoir to the radiator (green arrow).
Figure 3

There are three coolant lines: the left side line that connects the radiator to the thermostat and reservoir (red arrows), the right side hose that connects the radiator to the water pump and heater core (yellow arrows) and the hose that connects the coolant reservoir to the radiator (green arrow).

Begin by removing the overflow hose from the clips along the front of the shroud where it runs to the overflow reservoir (red arrow) and release the clip where it mounts to the oil cooler (yellow arrow).
Figure 4

Begin by removing the overflow hose from the clips along the front of the shroud where it runs to the overflow reservoir (red arrow) and release the clip where it mounts to the oil cooler (yellow arrow).

Use a flathead screwdriver and release the quick release clip from the connection from the thermostat to the radiator and wiggle/pull the hose out (red arrow).
Figure 5

Use a flathead screwdriver and release the quick release clip from the connection from the thermostat to the radiator and wiggle/pull the hose out (red arrow).

Using a flathead screwdriver release the quick release clip and pull the upper section of the hose from the water pump to radiator (red arrow).
Figure 6

Using a flathead screwdriver release the quick release clip and pull the upper section of the hose from the water pump to radiator (red arrow).

Remove the hose from the bottom of the reservoir (yellow arrow) to the radiator by using a flathead screwdriver to release the quick release connection and wiggle/pull the hose from the radiator (red arrow).
Figure 7

Remove the hose from the bottom of the reservoir (yellow arrow) to the radiator by using a flathead screwdriver to release the quick release connection and wiggle/pull the hose from the radiator (red arrow).

You will need to remove the radiator fan to replace the radiator.
Figure 8

You will need to remove the radiator fan to replace the radiator. Please see our article on radiator fan replacement for additional information.

With the fan removed you can see the two lines running to the transmission cooler (red arrows).
Figure 9

With the fan removed you can see the two lines running to the transmission cooler (red arrows).

Use a 25mm wrench and remove the lines (red arrow).
Figure 10

Use a 25mm wrench and remove the lines (red arrow). Make sure to cover the transmission lines, as you do NOT want any contaminants getting into the lines. You are going to lose some fluid so be prepared to catch and dispose of it correctly as well as refill the fluid to the proper level.

Remove the front grille to access the connection between the radiator and condenser (red arrows).
Figure 11

Remove the front grille to access the connection between the radiator and condenser (red arrows). Please see our article on front grille removal for additional assistance.

With the grille removed pull back the rubber air dam and squeeze in the release tabs on each side of the radiator (red arrows) and push the top of the radiator back from the condenser.
Figure 12

With the grille removed pull back the rubber air dam and squeeze in the release tabs on each side of the radiator (red arrows) and push the top of the radiator back from the condenser.

Under the vehicle the radiator is connected to the condenser in three areas as well as sitting in rubber grommets on the frame.
Figure 13

Under the vehicle the radiator is connected to the condenser in three areas as well as sitting in rubber grommets on the frame. The lower plastic tab on the condenser sits in the radiator (red arrows). In addition, there are two mounts on the condenser that slip into the radiator (yellow and green arrows). Release the lower clips. Then slide the top of the radiator back towards the engine.

With the lower clips undone tilt the radiator back and pull it up and out of the engine bay.
Figure 14

With the lower clips undone tilt the radiator back and pull it up and out of the engine bay. Installation is the reverse of removal. Remember to refill and bleed the coolant system as well as top up the level on the power steering fluid.


Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Wed 12/7/2016 02:55:10 AM