Radiator: Service and Repair

Radiator

Special tools, testers and auxiliary items required

• Drip tray for workshop crane (VAS 6208)

• Old oil collecting and extracting device (V.A.G 1782 )

Removing

• When assembled correctly, radiator and condenser can show slight impressions on fins. This is not damage. Radiators or condensers should not be replaced because of slight impressions like these.

- Remove front engine cover - arrows -.





CAUTION!
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 on noise insulation.





- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation. Rear section of noise insulation remains installed.





- Remove front bumper cover.

- Place drip tray for workshop crane (VAS 6208) under engine.





- Disconnect coolant hose - arrow - from lower left of radiator and drain coolant.

- Disconnect coolant hose from lower right of radiator - arrow -.





- Disconnect top coolant hose - right arrow - from radiator.





• Ignore - left arrow -.

Vehicles with automatic transmission:

- Remove bolts - arrows -.





- Remove air duct - 1 - and - 2 -.

• Observe the rules of cleanliness for working on automatic transmissions.





- Place old oil collecting and extracting device ( V.A.G 1782) under engine.

- Remove upper and lower ATF lines - arrow - on cooler.

- Tie ATF lines up to longitudinal member to prevent fluid from escaping.

All:

- Separate left and right electrical connectors - 3 - of horns - 2 -.





• Ignore - 1 -.

- Remove crossmember for bumper - arrows -.





- Remove left and right air guides at radiator - arrows -.





- Unclip Outside Air Temperature Sensor (G17) - 2 - from bracket.





- Remove power steering cooling coil bolts - 3 - and - 4 - hydraulic hoses remain connected.

- Disconnect electrical harness connector - 1 - at High Pressure Sensor (G65).

CAUTION!
The air conditioning refrigerant circuit must not be opened.

- Remove bolts - arrows -.

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

- Pivot condenser downward with lines connected.

- Release both radiator retaining pins and remove by pulling upward - arrows -.





- Pivot radiator forward, pull up and remove.

Installing

Installation is in reverse order of removal, noting the following:

- Remove old O-ring - 2 - in coolant hose - 3 -.





- Moisten new O-ring with coolant additive and install it in the coolant hose.

- Press coolant hose onto radiator - 1 - until it engages audibly.

- Press coolant hose on again and pull to make sure connection is engaged correctly.

- Install ATF lines.

- Install front bumper cross member.

- Install front bumper cover.

- Fill with coolant => [ Filling ] Procedures.

• Complete coolant must be replaced if the radiator was replaced.

- Check ATF level.

Tightening Specifications