Radiator: Service and Repair

Radiator

Special tools, testers and auxiliary items required

• Refractometer (T10007)

• Drip tray (V.A.G 1306) or drip tray for workshop crane (VAS 6208)

• Torque wrench (V.A.G 1331)

• Spring-type clip pliers (VAS 5024A)

• Adapter (V.A.G 1274/8)

• Cooling system charge unit (VAS 6096)

Removing

CAUTION!
Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

• Ensure sufficient clearance to all moving or hot components.

• When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work.

• Hoses are secured with spring-type clips. When performing repairs, use new spring-type clips.

• Pliers for spring clamps (VAS 5024A) or Hose clamp pliers (V.A.G 1921) are recommended for installing spring clamps.

• When installing coolant hoses, make sure they are free of stress and do not come into contact with other components (observe markings on coolant connections and hoses).

• Always replace gaskets and seals.

• Arrows on coolant pipes and coolant hoses must line up across from each other.

Perform cooling system leakage test with cooling system tester (V.A.G 1274) and the adapter (V.A.G 1274/8) and adapter (V.A.G 1274/9).

- Drain the coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.

- Remove the fan support with the coolant fans => [ Coolant Fans ] Service and Repair.

- Unscrew air guide on lock carrier - arrows -.





- Disconnect the coolant connection at upper radiator (quick-release coupling).

- Remove the left air duct hose, by lifting the retaining clips - arrows - slightly.





- Remove bolts - arrows - from radiator.





- Remove radiator downward. Push the radiator slightly upward and then lower it downward in order to get by the charge air cooler connection.

Installing

Installation is performed in reverse order. When doing this note the following:

• Replace coolant if a new radiator was installed.

• Fill with coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.

Tightening Specifications