Radiator: Service and Repair

Radiator, removing and installing

Special Tools and Equipment





^ VAG 1306 drip tray for VAG 1 202A

Removing
- Remove front bumper:

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.





- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.





- Loosen mounting parts -1 to 4- and remove noise insulation.
- Place VAG1306 Drip Tray beneath engine.





- Turn radiator drain plug -2 counter clockwise, if needed attach accessory hose to connection flange and drain coolant.
- Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.





- Disconnect left coolant hose from radiator (arrow)





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





- Disconnect top coolant hose from radiator (arrow).





Vehicles with automatic transmission
- Remove cover -1- in engine compartment (right side).





- Remove bolts (arrows).
- Remove air guide -1-.

Note: Observe the rules of cleanliness for working on automatic transmissions:

- Place an oil receptacle underneath.





- Disconnect top (arrow) and bottom ATF lines from radiator:
- Tie up ATF lines to top of long member to prevent fluid from escaping.





All:
- Remove air guides from left and right of radiator (arrows).





- Unclip temperature sensor -2- for outside temperature display from bracket.
- Remove bolts -1- and -4- and remove power steering cooling coil, hoses remain connected.
- Disconnect harness connector -3- at High Pressure Sensor -G65-.

WARNING: Do not open refrigerant circuit for A/C system.

- Remove condenser mounting bolts (arrows).

Note: To prevent damage to the condenser as well as to the coolant lines/hoses, make sure the lines and hoses are not overstretched, kinked or bent.

- Carefully swing condenser downward and move aside.





- Unlock both radiator retaining bolts and remove by pulling upward (arrows).
- Tilt radiator forward, pull up and remove.

Installing
Installation is reverse of removal, noting the following:

- Install front bumper
- Top up coolant.

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

Vehicles with automatic transmission
- Secure ATF line:

- Check ATF level:

Component Tightening Torques (Part 1 Of 6):

Tightening torque