Audi Workshop Service and Repair Manuals

Removing and installing radiator Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921-

t  Drip tray for workshop hoist -VAS 6208-

Removing –  Remove front left cover -arrows-.

–  Unscrew bolt -arrow- and remove cover over coolant expansion tank.

–  Unplug electrical connector -right arrow- at continued circulation coolant pump -V51- on right side of radiator cowl. –  Unscrew bolts -left arrows- and move continued coolant circulation pump -V51- clear to one side (coolant hoses remain connected). –  Unscrew bolts for radiator cowl which are accessible from above.

–  Unbolt bracket for headlight range control sender in wheel housing (left-side, top) -arrows-.

–  Remove centre noise insulation -arrows-.

–  Remove left noise insulation -arrows-.

–  Remove right noise insulation -arrows-.

–  If fitted, detach power steering line from connecting pipe for charge air coolers -arrows-.

–  Unbolt connecting pipe for charge air coolers on left side -arrows-.

–  Unbolt connecting pipe for charge air coolers on right side and detach air intake hoses from charge air coolers -arrows-. –  Remove connecting pipe for charge air coolers.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Turn drain plug -1- on radiator anti-clockwise and drain coolant (attach hose to connection if necessary). –  Disconnect coolant hose from radiator by pulling off retaining clip -2- at bottom.

–  Detach electrical connectors -arrows- for radiator fan on bottom left of radiator cowl. –  Move wiring clear. –  Unscrew bolts on radiator cowl (accessible from below) and remove the radiator cowl with both fans from below.

–  Unplug electrical connector -2- at radiator fan thermal switch -F18-. Vehicles with air conditioning:   WARNING The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Detach refrigerant line -1- from radiator.

All vehicles: –  Disconnect top coolant hose -1- at radiator. –  Remove bumper cover (front) → Rep. Gr.63.

Vehicles not equipped with air conditioning: –  Remove bolts -arrows- on left and right sides and remove radiator downwards. Vehicles with air conditioning:   WARNING The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Remove bolts -1- securing condenser and bolts -2- securing radiator. –  Detach radiator fan control unit -J293- from longitudinal member (left-side) in front of battery. –  Unscrew bolts for lock carrier at front. –  Loosen the upper bolts for lock carrier 2 turns. –  Carefully move lock carrier forwards as far as possible (2nd mechanic required) and remove radiator downwards. Installing Installation is carried out in the reverse order; note the following:   Note t  If there are slight impressions on the fins, refer to → Chapter. t  Renew O-rings in coolant hose connections. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Fit mountings -3- and -4- on radiator as illustrated. 1 -  Bolt, 15 Nm 2 -  Radiator fan thermal switch -F18- –  Fit securing bolts for radiator (the help of a 2nd mechanic is required). –  Install lock carrier with attachments → Rep. Gr.50. –  Install bumper cover (front) → Rep. Gr.63. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Radiator cowl to radiator	10
Radiator fan thermal switch -F18- to radiator	35
Refrigerant line to radiator	10
Condenser to radiator	10
Radiator to lock carrier	15
Connecting pipe for charge air coolers to longitudinal member	20
Hose clips for air hoses	3.5