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   Note Even when the radiator and condenser are correctly installed, slight impressions may be visible on the fins of these components. This does not mean that the components are damaged. If the fins are only very slightly distorted, this does not justify renewal of the radiator or the condenser. Engine cover panel (version 1): –  Pull dipstick -1- out of guide tube. –  Lift engine cover panel at sides -arrows 2- and pull off towards front -arrow 3-. –  Re-insert dipstick in guide tube.

Engine cover panel (version 2): –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

All vehicles (continued): –  Remove engine compartment seal from lock carrier and wing panel flanges. –  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct (bottom) together with air hose.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Unscrew air duct at lock carrier -arrows-.

Fuel filter - version 1: –  Lift fuel filter out of bracket -arrow- with hoses connected and move it aside.

Fuel filter - version 2: –  Slacken bolt -1- one turn. –  Remove bolt -2- and nut -3-. –  Move fuel filter aside with hoses attached.

All vehicles (continued): –  Unscrew bolts -1- for lock carrier (right-side).   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. –  Unscrew bolts -2- and -3- at brackets for refrigerant pipes.

–  Remove bolts -4- and move crash sensor (right-side) with wiring to one side.   Note Disregard items marked -1, 2, 3- and -arrows-.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Unplug electrical connector -2- at charge pressure sender -G31-/intake air temperature sender -G42-. –  Remove bolt -4-. –  Remove front air pipe with air hose by lifting retaining clips slightly -1- and -3-.

–  Remove air intake hose (right-side) by lifting retaining clips -arrows- slightly.   Caution Seal opening of charge air cooler with a piece of clean foam or similar to prevent coolant from entering.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Pull out retaining clip at the bottom -arrow- and disconnect coolant hose from radiator.

–  Unplug electrical connector -1-. –  Unscrew the bolts -arrows- and remove radiator cowl from below.

–  Also detach upper coolant hose on oil cooler -arrow-, and drain off remaining coolant.

–  Detach top coolant hose from radiator -arrow-.

–  Unscrew bolts -arrows- on backside of radiator. –  Lift out radiator from above. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals and O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Adhere to the instructions for installing air pipes and hoses with plug-in connectors → Chapter. –  Install crash sensor → Rep. Gr.69. –  Fill cooling system → Anchor. –  Check headlight adjustment → Booklet808. Tightening torques

Component	Nm
Radiator to charge air cooler	5
Radiator cowl to radiator	5