Radiator: Service and Repair

Radiator

Special Tools and Equipment
- Old oil collecting and extracting device -VAG 1782-
- Drip tray -VAS 6208-

Removing
- Remove front bumper cover

Note: Drained coolant must be stored in a clean container for disposal or reuse

WARNING Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

- Open cap of coolant expansion tank.





- Loosen screws or quick-release fasteners -1- and -2- and remove front noise insulation.
- Place -VAS 6208- under engine.

Vehicles with Drain Plug





- Rotate radiator drain plug -2- at cooler left and if necessary, position assiting hose on supports and allow to drain.

Vehicles without Drain Plug
- Remove securing clamps and remove engine coolant temperature (ECT) sensor (on Radiator) -G83- -3-.
- Remove engine coolant temperature sensor from supports and drain coolant.

All:
- Remove coolant hose from cooler by removing retaining clip -1- downward.





- Disconnect left coolant hose from radiator -arrow-.





- Remove cover -1- in engine compartment (left side).





- Disconnect top coolant hose -arrow- from radiator.

Vehicles with Multitronic transmission 01J or automatic transmission 01V





- Remove cover -1- in engine compartment (right side).
- Remove the bolts -arrows-.





- Disengage evaporative emission (EVAP) canister purge regulator valve -N80- -1- from air guide.
- Remove the air duct -2-.

Note Observe the rules of cleanliness for working on transmissions

- Place -V.A.G 1782- under engine.





- Remove upper and lower ATF lines -arrow- from cooler.
- Tie the ATF lines up to the longitudinal member to prevent fluid from escaping.

All:





Remove the left and right air guides from radiator -arrows-.





- Unclip the outside air temperature sensor -G17- -2- from thebracket.
- Remove power steering cooling coil bolts -3- and -4- hydraulic hoses remain connected.
- Disconnect electrical harness connector -1 - at high pressure sensor -G65-.

WARNING The air conditioning refrigerant circuit must not be opened.

- Remove the bolts -arrows-.

Note To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.





- Pivot the condenser downward with lines connected. Release both radiator retaining pins and remove by pulling upward -arrows-.
- Swivel cooler forward and remove upward.

Installing
Installation is in reverse order of removal, note the following:

Note Secure all hose connections using hose clamps appropriate for the model type. Refer to the electronic parts catalog ETKA.

Vehicles with Multitronic transmission 01J or automatic transmission 01V

- Install ATF lines.

All:

- Install the front bumper cover.
- Fill with coolant.

Note: Complete coolant must be replaced if the radiator was replaced.

Vehicles with Multitronic transmission 01J or automatic transmission 01V

- Check ATF level

Tighening Specifications
Condenser to lock carrier 10 Nm
Cooling coil for power steering to lock carrier 9 Nm