Radiator: Service and Repair

Radiator And Coolant Fan, Removing And Installing

Special tools, testers and auxiliary items
- Pliers VAG 1921 for spring-type clips





Cooling System Components, Body Side
1 Mounts
2 Bolt. Tighten to: 10 Nm (7 ft lb)
3 Radiator - always replace coolant when replacing
4 Coolant hose, upper - to connector pipe
5 Coolant hose, lower - To coolant pump
6 V-Belt for auxiliary fan -9-. Only with optional equipment
7 Guide ring - attached to fan shroud -1O- with clips
8 Coolant fan -V7-
9 Auxiliary fan - Only with optional equipment
10 Fan shroud - note installation position
11 Connector
12 Cover
13 Expansion tank
14 To coolant pipe or connector flange
15 To ATF cooler for vehicles with automatic transmission
16 To cylinder head
17 To upper coolant hose
18 Cap. Test pressure: 1.3-1.5 bar (19-22 psi)
19 Coolant Fan Control (FC) thermal switch -F18-. Tighten to: 35 Nm (26 ft lb)
20 Rubber bushing

Removing
- Drain coolant. Refer to Cooling System, Service and Repair. Service and Repair
- Disconnect coolant hoses from radiator.
- Disconnect harness connectors from coolant fan thermal switch F18 and coolant fan.
- Remove both radiator mounting bolts.
- Remove lock carrier (radiator support) with attachments. Refer to Body and Frame, Service and Repair. Service and Repair
- Lift out radiator, coolant fan and air guide housing.

Vehicles with air conditioner
Refer to additional information and instructions for removal and installation.

Installing
Install in the reverse order of removal, noting the following.
- Cooling system, filling - refer to Cooling System, Draining and Filling
- Electrical connections and routing - refer to Diagrams and Diagrams, Diagrams Diagnostic Aids.
- Headlight adjustment - refer to Headlight Adjustments

Additional information for vehicles with A/C

WARNING!
The A/C refrigerant is toxic. The A/C circuit must only be opened by specially trained technicians using the proper tools and equipment.

CAUTION!
Disconnect brackets and support points only.
DO NOT open the air conditioning refrigerant circuit.
Refrigerant lines kink easily. DO NOT stretch or bend them

- Remove air cleaner (ACL) housing with intake air ducts.
- Remove retaining clamps from A/C receiver/dryer and allow to hang free.
- Remove retaining clamp(s) from A/C refrigerant lines.
- Separate condenser from radiator and pull it forward as possible.
- Remove radiator and coolant fan.
- Secure condenser to body so that refrigerant lines and hoses are out of the way but not stressed.
For additional information on Servicing A/C Components refer to Heating and Air Conditioning, Service and Repair. Service and Repair