Radiator Module

Radiator Module

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)

• Hose Clamps up to 25 mm Dia. (3094)

Removing

• The radiator module is comprised of the radiator, power steering fluid cooler, Air Conditioning (A/C) condenser, and transmission fluid cooler.

• When assembled correctly, the radiator and A/C condenser can show slight impressions on the fins. This 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 ] Service and Repair.

- Evacuate the refrigerant in the A/C system.

- Drain the coolant. Refer to => [ Coolant, Draining ] Coolant, Draining.

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

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






- Seal the transmission fluid cooler and pipes with sealing plugs.

- Remove the refrigerant line bolts - A - from the radiator.






- Seal the A/C condenser and pipes with sealing plugs.

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






- Clamp off the power steering hoses and remove.

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






- Remove the radiator grille - 1 -..






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

- Open the air guides on both sides of the air guide openings - 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 locking pins - B - on both upper radiator mounts - A - by pushing them in the - direction of the arrow - and then pulling upward.






- Remove both upper radiator mounts - A -.

- Remove the radiator module upward.

Installing

• Tightening specifications, refer to => [ Fan Shroud and Radiator Overview ] Service and Repair.

- 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 locking 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 ] Service and Repair.

- Install the transmission fluid lines.

- Drain the coolant system completely before filling. Refer to => [ Coolant System, Draining ] Coolant System, Draining.

- Fill the coolant system. Refer to => [ Coolant, Filling ] Coolant, Filling.

- Check the transmission fluid level.

- Install the noise insulation.