Radiator

Radiator

Special tools, testers and auxiliary items required

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

• Engine Bung Set (VAS 6122)

• Drip Tray for VAS 6100 (VAS 6208)

• Hose Clip Pliers (VAS 6362)

Removing

• The radiator module consists of the radiator (high temperature), the Air Conditioning (A/C) condenser and the transmission fluid cooler. It is not necessary to open the low temperature coolant system.

• The radiator and A/C condenser may have small indentations on the fins even when installed correctly. It is not damage. Radiators or A/C condensers should not be replaced because of slight impressions like these.

- Remove the fan shroud. Refer to => [ Fan Shroud ] Fan Shroud.

- Evacuate the refrigerant in the A/C system.

- Drain the high temperature coolant circuit. Refer to => [ Draining and Filling, High Temperature Coolant Circuit ] Draining and Filling, High Temperature Coolant Circuit.

- Place the used oil collecting and extracting device (V.A.G 1782) under the separating point on the transmission fluid cooler.

- Remove the bolt - A - and the connection from the transmission fluid cooler. Catch any fluid coming out.






- Remove the bolts - A - and the refrigerant lines from the A/C condenser.






- Lift the clamp and remove the lower coolant hose from the radiator.






- Remove the radiator grille - 1 -..






- Remove the license plate holder - 2 - and the center vent grille - 3 -.

- Remove the brackets - 1 and 2 - and then remove the center radiator for the charge air cooler from the radiator module. The coolant hoses - arrows - remain connected.






- Lift the retaining clip - 1 - and remove the upper coolant hose from the radiator.






- Remove the Secondary Air Injection (AIR) pump motor. Refer to => [ Secondary Air Injection Pump Motor V101 ] Service and Repair.

- Open the air guide on both sides of the air guide opening - arrow - and remove the bolts - A -.






- Remove the lower radiator mounts from the radiator module over the longitudinal members.

- Remove the bolts - arrow - (quantity: 3) from the air guide through the lowest air grille.






- Remove the bolt - arrow - next to the left and right headlamps.






- Push the radiator module toward the engine, open the clips - arrows - on the upper air guide on the radiator and remove it.






- Unlock the lock pins - B - on both upper radiator mounts - A - by pushing them in - direction of arrow - and then pulling upward.






- Remove both upper radiator mounts - A -.

- Remove the radiator module upward.

Installing

• For the correct tightening specifications, refer to => [ Radiator and Fan Shroud Overview ] Radiator and Fan Shroud Overview.

- Install the radiator module.

- Mount the upper radiator mount and tighten it.

- Install the radiator module into the upper radiator mount - A - and install the lock pins - B -.






- Install the lower radiator mount into the radiator module and tighten it.






- Push the clips - arrows - on the upper air guide into the radiator.






- Install the radiator grille - 1 -..






- Install the license plate holder - 2 - and the center vent grille - 3 -.

Further installation is performed in reverse order of removal, noting the following:

• Secure all hose connections with hose clamps that are specific to that model. Refer to the Parts Catalog.

• All the coolant must be changed if the radiator was replaced.

- Connect the coolant hoses with the connector coupling. Refer to => [ Connecting the Coolant Hose to the Coupling ] Radiator and Fan Shroud Overview.

- Install the automatic transmission fluid lines.

- Drain the coolant system completely before filling. Refer to => [ Draining and Filling, High Temperature Coolant Circuit ] Draining and Filling, High Temperature Coolant Circuit.

- Fill the high temperature coolant circuit. Refer to => [ Draining and Filling, High Temperature Coolant Circuit ] Draining and Filling, High Temperature Coolant Circuit.

- Check the transmission fluid level.

- Install the noise insulation.