Radiator: Service and Repair

Radiator

Special tools, testers and auxiliary items required

• Hose Clamp Pliers (V.A.G 1921)

• Drip Tray for Workshop Crane (VAS 6208)

Removing

• When assembled correctly, radiator and condenser can show slight impressions on fins. This is not damage. Radiators or condensers should not be replaced because of slight impressions like these.


Risk of scalding due to hot steam and hot coolant.

• When the engine is warm the cooling system is under pressure.

• Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

- Open cap of coolant expansion tank.

- Remove center noise insulation fasteners - 1 to 3 -.





- Disconnect electrical connector - 1 - at Engine Coolant Temperature (ECT) sensor (on radiator) (G83).





- Place (VAS 6208) under engine.

- Turn drain plug - arrow - on radiator left, place assisting hose on supports if necessary.

- Remove lower coolant hose - 2 - from radiator by removing retaining clamps.

- Also remove lower coolant hose to after-run coolant pump (V51) - arrow - and allow remaining coolant to drain.





- Remove front bumper cover.

- Disconnect secondary air hose at position indicated by - arrow -.





- Free up air hose to Secondary Air Injection (AIR) pump.

- Disconnect upper coolant hose - arrow - from radiator by removing retaining clip.





- Remove fan shroud upper bolts - upper arrow -.





- Free up coolant hose at bottom on fan shroud.





- Disconnect electrical connector - 3 - at secondary air injection (AIR) pump motor (V101) and free up electrical wiring.

- On vehicles with DSG transmission, remove coolant pipe bracket - 2 - to transmission oil cooler.

- Remove bolts - 1 -.

- Loosen bolt - 4 - and remove Secondary Air Injection (AIR) pump with bracket.

- Disconnect electrical harness connectors - 1 - for coolant fans at bottom on fan shroud.

- Remove mounting bolts for fan shroud at bottom - bottom arrows -.





- Pull out fan shroud downward with both fans.

- Remove left and right air ducts from radiator.






The air conditioning refrigerant circuit must not be opened.

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

- Remove condenser mounting bolts - 2 -.

- Remove bolts - 1 - at radiator.

- Swing radiator slightly toward rear.

- Disengage radiator upward and remove downward.

Installing

Installation is in reverse order of removal, note the following:

- Install the front bumper cover.

- Install Secondary Air Injection (AIR) pump. Refer to => [ Secondary Air Injection Pump ] Secondary Air Injection Pump.

- Fill with coolant => [ Filling ] Procedures.

Tightening Specifications