Radiator, Removing and Installing

Radiator, removing and installing

Special tools and equipment





^ Drip tray VAG 1306
^ Oil collector

Removing

Note: Coolant drained off must be collected in a clean container for disposal/re-use.

WARNING: Hot vapor/hot coolant may escape when opening expansion tank. When opening the expansion tank, wear gloves and other appropriate protection. Cover the cap with a rag and open carefully to relieve pressure slowly

- Unscrew cap of coolant expansion tank.





- Unfasten quick-release fasteners -1- and -2- and detach front noise insulation. Leave rear noise insulation in position.
- Remove front bumper.





- Remove drain plug (arrow) at thermostat housing and drain off coolant at engine.





- Remove left air duct (arrow) in front of auxiliary radiator.





- Detach coolant hose at bottom of radiator (arrow) and drain off remaining coolant.
- Place drip tray in position.

Note: Heed rules for cleanliness when working on automatic transmission:





- Unscrew ATF line at top and bottom of radiator (arrow).





- Remove air cleaner cover -2-.
- Remove air duct -1

Note: Pull out clips (arrows) using pry lever 80-200.





- Remove upper coolant hose (arrow) from radiator.





- Remove bolts (arrows) at air ducts on left and right of radiator.
- Pull out clips at bottom of air duct.

Note: Use pry lever 80-200 to pull out clips.





- Unclip temperature sensor -1- for ambient temperature gauge from holder and move wire clear.
- Remove power steering hydraulic fluid cooling coil bolts (arrows); do not open hydraulic fluid circuit.
- Tie up power steering hydraulic fluid cooling coil to one side.

CAUTION: Refrigerant circuit of air conditioner is never to be opened.

Note: So as not to damage condenser and refrigerant fines/hoses, take care not to strain, kink or bend lines and hoses.





- Disconnect connector -1- at high pressure sensor -G65-.
- Remove bolts (arrows).
- Detach condenser and swivel downward with lines connected.





- Release both retaining pins for radiator and lift up (arrows).
- Swivel top edge of radiator forward and lift up radiator.

Installing
Install in reverse order, paying attention to the following:
- Fill with coolant.

Note: The entire coolant must be replaced following radiator replacement.

- Attach ATF lines:
- Install front bumper.
- Check ATF level.





Tightening torques