Radiator: Service and Repair

Radiator

Special tools, testers and auxiliary items required

• Used Oil Collecting and Extracting Device (V.A.G 1782)

• Engine Bung Set (VAS 6122) for vehicles with multitronic transmission or automatic transmission 09L

• Drip Tray for Workshop Crane (VAS 6208)

• Hose Clamp Pliers (VAS 6362)

Removing

• If there are small impressions on the fins. Refer to => [ Coolers and Condensers ] Coolers and Condensers.

CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opening.

- Open cap of coolant expansion tank.

- Remove noise insulation.





- Remove front left and right wheel housing liners.

- Remove front bumper cover.

- Place Drip Tray for Workshop Crane (VAS 6208) under engine.





- Open drain plug - 1 - and allow coolant to drain.

- Then disconnect coolant hose - 2 - from radiator.

- Remove the lower left coolant hose - arrow - from the radiator; to do so lift the clamp.





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





• Ignore - left arrow -.

Vehicles with Multitronic transmission or automatic transmission 09L:

- Remove bolts - arrows -.





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

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

- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.

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





- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).

All:





- Remove bolts - 3 - and remove air duct.

- Remove bolts - 4 - and remove bracket for horns; leave electrical connections intact.

- Unfasten bracket - 2 - and - 5 - for headlamp.

- Remove nuts - 1 - and - 6 - and remove bumper.

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





- Remove power steering cooling coil bolts - 1 - and - 2 - hydraulic hoses remain connected.

- Remove air guides at left and right of radiator.

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

- Separate the electrical connector - 1 -.





- Remove the bolts - arrows -.

• Do not bend or stretch lines or hoses as A/C compressor and/or refrigerant lines/hoses may be damaged.

- Pivot the 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, note the following:

• Secure all hose connections with hose clamps appropriate for the model.

- Install ATF lines.

- Install the front bumper cover.

- Install front left and right wheel housing liners.

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





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

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

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

- Fill with coolant => [ Filling ] Procedures.

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

- Check ATF level.

Tightening Specifications