Audi Workshop Service and Repair Manuals

Removing and installing radiator with radiator cowl   Note t  Radiator and radiator cowl can only be removed and installed together as one unit. t  On more recent versions it is no longer possible to remove the condenser from the radiator with the refrigerant lines attached. This is described below under „version 2“. Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782- for vehicles with dual clutch gearbox 0B5

t  Engine bung set -VAS 6122- for vehicles with dual clutch gearbox 0B5

t  Drip tray for workshop hoist -VAS 6208-

Removing –  Remove front noise insulation -1- → Rep. gr.66.

–  Remove impact bar -5- → Rep. gr.63.

Vehicles with refrigerant lines (version 2): –  Remove condenser → Rep. gr.87.

Audi A4: –  Remove bracket for mounting for headlight → Electrical system; Rep. gr.94.

All vehicles (continued): –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Remove drain plug -1- and drain off coolant. –  Lift retaining clip -2- and disconnect coolant hose from radiator.

–  Detach connection from radiator (lift retaining clip -arrow-).

WARNING Risk of injury as the radiator fans may start up automatically. Unplug electrical connectors before starting to work in the area of radiator cowl. –  Unplug electrical connectors -1- and -2- for radiator fan (push retainer to the rear -arrow- and press down release catch).

Vehicles with dual clutch gearbox 0B5: –  Position used oil collection and extraction unit -V.A.G 1782- below connection point.   Note Observe rules for cleanliness when working on gearbox → Rep. gr.00. –  Unscrew bolts -arrows- and detach ATF lines from radiator.   Note Tie ATF lines up onto longitudinal member to prevent fluid escaping. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

All vehicles (continued): –  Lift retaining clips -1- and -2- and detach connection from radiator.

–  Remove bolts -arrows-. –  Detach air duct -1- from intermediate flange -2- for air cleaner housing.

Vehicles with hydraulic power steering: –  If fitted, release retaining clips -arrow A- and swivel power steering cooling pipe -1- to front -arrow B-. –  Lift power steering cooling pipe away from condenser and place onto engine.

All vehicles (continued): –  Release catches -arrows A- and detach air duct -1- on left and right -arrow B-.

–  Release retaining pins for radiator on both sides and pull out upwards -arrows-.

–  Remove bolts -1- on both sides and detach radiator bracket with radiator from lock carrier -arrow-. –  Slightly lower radiator.

Vehicles with refrigerant lines (version 1):   Caution Make sure that condenser and refrigerant pipes and hoses are not damaged. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Have a 2nd mechanic release retaining clips -1- in direction of -arrow A- and lift condenser -2- out of mounts on radiator -arrows B-. –  Pivot condenser forwards with refrigerant lines attached. All vehicles (continued): –  Detach radiator.

–  Press locking tabs on left and right sides of radiator cowl -arrow- and at the same time lift radiator cowl off radiator. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter   Note If there are slight impressions on the fins, refer to → Chapter. –  Attach air duct to intermediate flange for air cleaner housing → Rep. gr.24. –  Vehicles with dual clutch gearbox 0B5: Secure ATF-lines → Rep. gr.34.

–  Connect coolant hose with plug-in connector → Fig.. –  Audi A4: Install bracket for mounting for headlight → Electrical system; Rep. gr.94. –  Install condenser → Rep. gr.87. –  Install impact bar → Rep. gr.63. –  Fill up with coolant → Anchor.   Note The coolant in the entire system must be changed if the radiator is renewed. –  Vehicles with dual clutch gearbox 0B5: Check ATF level → Rep. gr.34.