Radiator: Service and Repair

Radiator

Special tools, testers and auxiliary items required

• Old Oil Collecting And Extracting Device (V.A.G 1782 ) only on vehicles with Multitronic/automatic transmission 01V:

• Drip Tray For Workshop Crane (VAS 6208) or Drip Tray (V.A.G 1306)

Removing

• Drained coolant must be stored in a clean container for disposal or reuse.

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

- Open cap of coolant expansion tank.

- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.





- Remove front bumper cover.

- Place Drip Tray For Workshop Crane (VAS 6208) or Drip Tray (V.A.G 1306) under engine.

Vehicles with coolant drain plug:

- Open coolant drain plug to coolant line at bottom of cooler.

Vehicles without coolant drain plug:

- Remove retaining clip - 1 - on the Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) - 2 -.





- Remove Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) from its supports and drain the coolant.

All:

- Disconnect lower coolant hose from radiator - arrow -.





- Disconnect upper coolant hose from radiator - arrow -.





Vehicles with Multitronic/automatic transmission 01V:

- Remove right cover - 1 - in the engine compartment, if equipped.





- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from the air guide.

- Remove bolts - arrows -.





- Remove air duct - 2 -.

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





- Place Old Oil Collecting And Extracting Device ( V.A.G 1782) underneath.

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

- Tie the ATF lines up to the longitudinal member to prevent fluid from escaping.

All:

- Remove the left and right air guides at radiator - arrows -.





- Unclip Outside Air Temperature Sensor (G17) - 2 - from the bracket.





- Remove power steering cooling coil bolts - 3 - and - 4 - hydraulic hoses remain connected.

- Disconnect the connector - 1 - on the High Pressure Sensor (G65).

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

- Remove bolts - arrows - for the condenser.

• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

- Pivot 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:

- Install front bumper cover.

- Fill with coolant => [ Filling ] Procedures.

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

Vehicles with Multitronic/automatic transmission 01V:

- Fasten the ATF lines.

- Check ATF level.

Tightening Specifications