Removal and Replacement

Radiator, removing and installing





Special tools, testers and auxiliary items required
^ Refractometer T10007
^ Drip tray V.A.G 1306
^ Torque wrench V.A.G 1331
^ Spring-type clip pliers VAS 5024

Removing
- Remove sound insulation.
- Remove front bumper.
- Drain coolant.
- Remove quick release couplings of coolant hoses from radiator.
- Disconnect harness connector from thermal switch.

Vehicles with automatic transmission
- Disconnect ATF lines from radiator.

Continued for all vehicles





- Remove cooling coil for power steering fluid - arrow - and let hang free; Do not open hydraulic fluid circuit.
- Remove upper radiator securing clips and remove radiator toward front.

Installing
Installation is performed in reverse order of removal. Note the following:

Vehicles with automatic transmission
- Check ATF level.

Continued for all vehicles
- Fill with coolant.
- Check harness connectors and routing.
- Check headlight adjustment, correct if necessary.

Additional information and assembly work on vehicles with air conditioning

Note: To prevent damage to condenser and also to the refrigerant lines and hoses, ensure that the lines and hoses are not stretched, kinked or bent.

- Remove retaining clamp(s) from refrigerant lines.
- Remove condenser from radiator and pull forward as far as possible.
- Secure condenser to body so that refrigerant lines and hoses are not stressed.
- Pull out radiator between condenser and lock carrier.