So I finally replaced the leaking radiator on my 240D today. I bought a new Behr- Hella from FCP-Euro which cost $195 including shipping. The job would have been really quick but re-attaching the engine oil cooler to the radiator proved to be a real nightmare. The problem stems from the fact that there is no way to secure the nuts on the inside of the channel where the cooler gets bolted. The original Mercedes radiator had the nuts pressed into the holes in the channel. The replacement doesn’t have these captive nuts so it is virtually impossible to keep them from falling away while installing the bolts since there basically is no access to the tight space in the channel. The lower one was the biggest problem which I eventually solved by wedging a thin piece of wood in the channel to keep the nut in place while installing the bolt. The wooden wedge had to be split and mangled into oblivion in order to extract it from this tight space with the oil cooler partially installed. I couldn’t just leave it there since it would interfere with the proper installation of the cooler. Luckily, I managed to get my finger in the channel to hold the upper nut in place while installing the upper mounting bolt. There was a lot of cursing and talking to myself while doing this job. The neighbors probably think that I’m insane!
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