Radiator: Service and Repair

Radiator and fan, removing and installing

Special tools and equipment





- T10007 Refractometer
- VAG1306 drip tray
- VAG1331 torque wrench (5 to 50 Nm)
- VAS5024 assembly tool for spring type clamps

Removing
- Remove noise insulation pan

Vehicles with A/C system
- Remove ribbed belt.
- Unbolt power steering vane pump with bracket and secure to body using wire; hoses remain connected

- Remove A/C compressor

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

- Observe additional notes and repair work.

Continuation for all vehicles
- Remove radiator grill





- Unscrew mounting bolts for lock carrier -1- at left and right.
- Unbolt expansion tank from lock carrier and set aside.
- Fold out lock carrier and cooler toward front (arrow).





- Unbolt hydraulic line -1- of power steering at radiator and set aside.
- Disconnect connector from thermal switch and radiator fan.

Note:
Mark connectors before disconnecting connectors to radiator fan.

- Now disconnect connector to right coolant fan -V35- and coolant fan -V7-.
- Drain engine coolant.
- Remove coolant hoses from radiator.
- Lift out radiator complete with intake air elbow and fan upward.

Installing
Installation is reverse of removal, noting the following:
- Install ribbed belt.
- Top up coolant.
- Check headlight adjustment, correct if necessary.

Additional notes and assembly steps for vehicles with A/C system

WARNING!
Do not open refrigerant circuit for A/C System.

Note:
Do not over-expand, kink or bend lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

- Unscrew retaining clamp(s) for refrigerant lines.
- Remove condenser from radiator and pull forward as far as possible.
- Lift out radiator upward.
- Secure condenser to body so that the refrigerant lines/hoses are not burdened.