Mercedes-Benz W203 C-Class Radiator Replacement

The radiator on the W203 is not that difficult to replace, and there is just a small 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.

Begin by disconnecting the ground from the battery and making sure it can not accidentally make contact again while you are working.

You will need to remove the two air inlet ducts as well as the front engine cover. Remove each duct by compressing them towards the engine and slipping them off the air inlet.

With the ducts off remove the front engine cover. It pulls up and away from the engine. The cover is held on by five clips and will easily come off with hand pressure.

In front of the radiator, you will find the horns. Remove the four electrical contacts for the two horns and using a 10mm socket remove the horns from the center bracket.

Cut the zip tie that holds the horn wiring harness to the center bracket on the cross member.

Remove the 10mm bolt that holds the power steering line to the center bracket.

There are two 10mm bolts holding the center bracket to the front of the car from the back of the bracket. Use a small wrench and working from behind the bracket remove these two bolts.

Unscrew the two hood stops (one on each side), they simply unscrew and then pull out. This will allow you to compress the plastic clip from the radiator shroud when removing the cross member.

Use a 10mm wrench and remove the two bolts holding down the hood releases on both sides of the cross member.

Pull the hood releases up through the cross member and detach the release cables from the release mechanism.

Remove the upper two 10mm bolts on each side of the cross member.

Compress the two plastic clips holding the wiring harness to the cross member and push them down through the holes in the cross member.

Lift the cross member out and flip it over. Next you need to remove the hood release cable on the right side. It just slips out of its plastic retaining clip.

Remove the two air inlet ducts. They have a small clip on the top, push it down and slide the duct off. Undo the electrical connection from the wiring harness to the fan assembly.

Carefully remove the fan assembly from the car. Take care that you do not damage the four clips (two on each side) that help secure the assembly to the radiator.

Next safely jack up and support your car. With the car safely off the ground you will need to remove the engine tray. There are six 8mm bolts holding the tray on, the rear two also help hold the transmission tray. If you are going to leave the transmission tray on, remove the rear two bolts first, lower the engine tray, reattach the transmission tray bolts, then remove the remaining four bolts on the engine tray.

With the tray removed you will see radiator drain plug on the lower left front of the car. Place a catch bucket or tray under the plug and use a large flat head screw driver to open the drain plug.

The fluid will come out slowly at first so open the tank cap to break the vacuum and help speed things up. The fluid drains out a small spigot facing rearward and not through the red plug.

Remove the upper radiator to coolant pump hose. Mercedes-Benz uses quick disconnect attaching point where the hose connects to the radiator, but sometimes the wire clip you need to pull out is facing something that does not allow it to be pulled straight out. If this is the case just unclip it from the radiator and then pull the hose out. You will need to reinstall it before reattaching the hose.

Move to the right upper part of the radiator and remove the quick disconnect for the upper automatic transmission fluid line. Remove the bracket securing the line to the mount on the other line using your 10mm wrench. Slip the line out of the radiator, there will be some fluid that runs out so be prepared to catch it and dispose of it and the manner regulated by the area of the country you live in.

On the lower right part of the radiator remove the quick disconnect coolant hose, again this hose is lower than the radiator drain plug so be prepared to catch and dispose of the fluid. Next disconnect the lower automatic transmission line.

Move to the front of the radiator and squeeze together and release the two plastic clips (one on each side) holding the radiator to the A/C condenser. The radiator is now free and can be lifted out of the engine compartment. Take care of the four mounting points in the ends of the radiator when removing and reinstalling. Installation is the reverse of removal.

https://www.pelicanparts.com/techarticles/Mercedes-W203/WATER-Replace_the_Radiator/WATER-Replace_the_Radiator.htm

Time: 3 hours
Tab: $175
Tools: 10mm socket and wrench, pliers, diagonals
Applicable Models: Mercedes-Benz C320 (2001-04)
Parts Required: New radiator:
Hot Tip: Work on a cool car
Complementary Modification: New hoses

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