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

Nick Czerula

Time:

2 hours2 hrs

Tab:

$350

Talent:

***

Tools:

T30 Torx driver, 10mm socket, Flathead screwdriver

Applicable Models:

Mercedes-Benz W211 (2003-09)

Parts Required:

Radiator, coolant reservoir vent hose

Hot Tip:

Work with a cool engine

Performance Gain:

Proper engine cooling.

Complementary Modification:

Inspect or replace coolant hoses

Automobile radiators are made out of a core of linked narrow passages connected via two side tanks. The core is metal and made of stacked layers, pressed and soldered together to form channels. Traditionally radiators were made of brass or copper cores and attached to brass side tanks. Radiators in today's vehicles are made of aluminum cores attached to plastic side tanks. This keeps cost down and saves weight.

In automobiles with a liquid-cooled engine, a radiator is connected to passages in the engine where liquid coolant is pumped through via a water pump. This liquid is a mixture of water and glycol (to prevent freezing).

The radiator cols the engine by transferring the heat from the fluid inside the engine to the outside air. Radiators are also used to cool transmission and power steering fluids.

When a radiator begins to fail, you'll notice that the car tends to overheat at high engine speed, such as driving on the highway. When you accelerate, the engine temperature will rise, when you idle the engine it will return to normal range. Now, this is not always indicative of a failing radiator, but a good starting point. Of course there are also leaks that occur at the side tanks of the radiator and the plastic side tanks can crack, causing major loss of engine coolant. You will have to remove the electric cooling fan to replace the radiator. These cooling fans are troublesome. I would suggest replacing it while you have it out. Inspect both radiator hoses and replace if necessary. Check for dry rot or splitting and examine to see that the sealing O-rings are in good shape.

In this article, I'll go over the steps involved with replacing the radiator on W211 models. Be sure to work with a cool engine and confirm the cooling system lacks pressure before opening the cooling system.

Remember your car may have been serviced before and parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve as they grow older. If something seems different, let us know and share your info to help other users. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Remove engine splash shields. See our tech article on engine splash shield removing.

Drain cooling system. See our tech article on cooling system draining and filling.

Working at the engine cover (red arrow), pull off the two front sir duct hoses (green arrows).
Figure 1

Working at the engine cover (red arrow), pull off the two front sir duct hoses (green arrows).

To detach the ducts, pull the straight off the engine cover / air filter housing.
Figure 2

To detach the ducts, pull the straight off the engine cover / air filter housing. Then pull the front of the duct out of the radiator support and remove from the engine. Repeat this step for each duct.

Lift up and remove the front engine cover.
Figure 3

Lift up and remove the front engine cover.

Then, remove radiator cooling fan (green arrow).
Figure 4

Then, remove radiator cooling fan (green arrow). See our tech article on radiator cooling fan replacing.

There are ducts that run through the sides of the radiator.
Figure 5

There are ducts that run through the sides of the radiator. At each side is a duct in the front and rear. Start by removing the engine compartment side duct (green arrow) by pulling it straight off. Left side shown, the right side is similar.

Working at the left side radiator hose, use a flathead screwdriver to lever out the coolant hose retaining clip (green arrow).
Figure 6

Working at the left side radiator hose, use a flathead screwdriver to lever out the coolant hose retaining clip (green arrow). Be sure to pull retaining clip out until it rests at the stop (blue arrow).

Pull radiator hose straight off radiator in direction of red arrow to remove.
Figure 7

Pull radiator hose straight off radiator in direction of red arrow to remove. This can be tricky. The hoses have been attached to the radiator for quite a while and may not come off easily. You will want to pull the hose off, while rocking it back and forth. Be careful not to damage the hose if you plan to reuse it. Inspect the sealing O-ring (blue arrow) before reinstalling. If it is dry rotted or cracked, replace the hose or O-ring.

Move to right side of the radiator and remove the four hoses.
Figure 8

Move to right side of the radiator and remove the four hoses. When removing the small transmission cooler lines, be sure to seal them as soon as they are removed. You don't want any engine coolant or debris entering the hose, transmission damage may occur.

Next the air dam and duct at the front of the radiator have to be removed.
Figure 9

Next the air dam and duct at the front of the radiator have to be removed. Start by removing the plastic rivets at the side of radiator support. Working at the left side of the radiator support, lever the center pin up (red arrow), then pull the rivet out of the radiator support.

Move to the center of the plastic air dam, pull the hood pin panel (red arrow) away from the radiator and move the dam (blue arrow) above it.
Figure 10

Move to the center of the plastic air dam, pull the hood pin panel (red arrow) away from the radiator and move the dam (blue arrow) above it.

Back to the left side of the radiator, pull the air dam (blue arrow) away from the radiator (red arrow).
Figure 11

Back to the left side of the radiator, pull the air dam (blue arrow) away from the radiator (red arrow). Then unclip the air dam (green arrow) from the connecting duct (yellow arrow). Remove the connecting duct from the dam.

Pull the air dam away from the radiator and detach it from the radiator support.
Figure 12

Pull the air dam away from the radiator and detach it from the radiator support.

Move to the right side of the radiator, pull the air dam away from the radiator.
Figure 13

Move to the right side of the radiator, pull the air dam away from the radiator. Then unclip the air dam (green arrow) from the connecting duct (red arrow). Remove the connecting duct from the dam.

This photo shows the air dam (green arrow) detached from the connecting duct (red arrow).
Figure 14

This photo shows the air dam (green arrow) detached from the connecting duct (red arrow).

Now that the air dam is out of the way, you have to detach the power steering cooling loop (green arrows) and A/C condenser (red arrow) from the radiator.
Figure 15

Now that the air dam is out of the way, you have to detach the power steering cooling loop (green arrows) and A/C condenser (red arrow) from the radiator. Start at the right side of the cooling loop (blue arrow). Working at the right side of the power steering cooling loop (green arrows), squeeze the retaining tabs (yellow arrows) together and pull the cooling loop off the mount at the radiator.

Move to the left side of the cooling loop, squeeze the retaining tabs (red arrow) together and pull the cooling loop off the mount at the radiator.
Figure 16

Move to the left side of the cooling loop, squeeze the retaining tabs (red arrow) together and pull the cooling loop off the mount at the radiator. I like to reach into the engine compartment and push the hoses (green arrow) toward bumper while squeezing the retaining tabs. It makes detaching the loop much easier.

Next, detach the A/C condenser, squeeze the retaining tabs (red arrows) together and pull the condenser off the mount at the radiator.
Figure 17

Next, detach the A/C condenser, squeeze the retaining tabs (red arrows) together and pull the condenser off the mount at the radiator. Left side shown, the right side is similar.

Next up the lower air dam has to be detached from the radiator.
Figure 18

Next up the lower air dam has to be detached from the radiator. There are two retaining tabs, at each lower corner of the dam. Working under the vehicle at the right lower side of radiator, squeeze the retainer (red arrow) and pull dam out of radiator (green arrow). Right side shown, the left side is similar.

This photo shows the retaining tab removed (yellow arrow).
Figure 19

This photo shows the retaining tab removed (yellow arrow). Note the lower portion of the retainer, this has to be disengaged as you squeeze. Right side shown, the left side is similar. When reinstalling the air dam, be sure the condenser is out of the way, then feed the upper tab (red arrow) into the radiator (blue arrow), then engage retaining clip. The air dam will remain in the vehicle.

Once the air dam is detached, move the condenser (green arrow) away from the radiator (red arrow).
Figure 20

Once the air dam is detached, move the condenser (green arrow) away from the radiator (red arrow). Make sure the power steering loop and air dam are also out of the way.

To the remove radiator, pull out of radiator support upward (red arrow) and out of engine compartment.
Figure 21

To the remove radiator, pull out of radiator support upward (red arrow) and out of engine compartment.

Lower the new radiator into engine compartment and install on support.
Figure 22

Lower the new radiator into engine compartment and install on support. Be sure both rubber insulators are properly engaged with the tab on body and slot in radiator. You will want to check that the radiator is properly engaged to lower radiator support. The way I do this is, once radiator is installed without the fasteners, I pull on the bottom of the radiator, it should stay put. If it pulls out, you did not get it in correctly. You'll have to lift if up and try again. Check that the upper mounts are tight. If needed, remove the center pin (yellow arrow) by pulling it straight up. Then unscrew to tighten mount or screw in to loosen. This adjusts the depth of the insulator (red arrow) into the radiator slot (green arrow). Once it is installed properly, reassemble hoses and radiator support covers. Then install the cooling fan and fill and bleed cooling system. Run engine and double check for coolant leaks. 

Bookmark and Share
Comments and Suggestions:
Richard T Comments: Got anything on 1998 E320 4MAtic radiator? I have a leaking over low tube on the lower driver side rail that appears to be disconnected and leaking.

Can you email me the 1998 differences?
September 14, 2016
  Followup from the Pelican Staff:
This may help:
http://www.pelicanparts.com/techarticles/Mercedes-Benz/18-WATER-Water_Pump_Replacement/18-WATER-Water_Pump_Replacement.htm

Other articles here:


http://www.pelicanparts.com/techarticles/Mercedes-Benz/18-WATER-Water_Pump_Replacement/18-WATER-Water_Pump_Replacement.htm - Nick at Pelican Parts
 
Kunle Adegboye Comments: I like the instructions and steps. Easy to follow. Thanks!
July 23, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Brian e Comments: The article seems to have missing information and bad links. I'm looking to replace the radiator on my 04 w211 e55amg. Could you please email me the correct instructions. Thank you
October 21, 2015
  Followup from the Pelican Staff: Yes, the article seems broken. We appreciate it. I will have the article updated. - Nick at Pelican Parts  
Andrew Comments: Your guide has pics for radiator and story for checking codes. Clicked on radiator replacing and takes me to checking codes page. Not sure what happened....
September 14, 2015
  Followup from the Pelican Staff: Thanks for catching that. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 
lark3622 Comments: your 211 rad replace is all fubar. Shows pics of rad replace with How to use a scan tool verbage/story.
somethin funy goin on around here.
March 18, 2015
  Followup from the Pelican Staff: WHOA. Thanks for catching that. I will have the page fixed. - Nick at Pelican Parts  

  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: Sat 12/3/2016 02:45:28 AM