Radiator: Service and Repair

Radiator

Special tools, testers and auxiliary items required

• Old oil collecting and extracting device (V.A.G 1782 ) (only for vehicles with automatic transmission)

• Drip tray for workshop crane (VAS 6208)

• Spring-type clip pliers (VAS 5024 A)

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 or hot coolant may escape when opening.

- Open cap of coolant expansion tank.

- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.





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





- Remove front bumper cover.

- Bring lock carrier into service position. Refer to => [ Lock Carrier, Moving into Service Position ] Lock Carrier, Moving Into Service Position.

- Place drip tray for workshop crane (VAS 6208) or drip tray (V.A.G 1306) under engine.





- Open drain plug - arrow - from lower left coolant hose and drain coolant.

- Disconnect lower coolant hose from radiator - arrow -.





- Disconnect coolant hose - 2 - at upper left of radiator.





• Ignore - 1 -.

- Remove bolts - arrows -.





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

Vehicles with automatic transmission:

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

• Automatic Transmission 09L. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle

• Continuously Variable Transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle





- Place old oil collecting and extracting device ( V.A.G 1782) underneath.

- Disconnect ATF-lines at top - arrow - and bottom of radiator.

• Automatic transmission 09L. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle

• Continuously variable transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle

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

All:

- Disconnect left and right electrical connectors - 3 - of horns - 2 -





• Ignore - 1 -.

- Remove bumper - arrows -.





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





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





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

- Pull off connector - 1 - from High Pressure Sensor (G65).

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

- Remove bolts - arrows - for condenser.

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

- 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. Refer to => [ Cooling System, Draining and Filling ] Procedures.

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

Vehicles with automatic transmission:

- Fasten ATF lines:

• Automatic transmission 09L:. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle

• Continuously variable transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle

- Check ATF level

• Automatic transmission 09L. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle

• Continuously variable transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle

Tightening Specifications