Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Pliers V.A.G 1921 for spring type clips

Removing

• ‒ Drain coolant
• ‒ Removing front bumper:

=> General body repairs; Repair group 63; servicing bumper; removing and installing front bumper

• ‒ Pull coolant hoses off radiator.
• ‒ Pull connectors off thermo-switch and radiator fan.
• ‒ Remove headlights:

=> Electrical system; Repair group 94; servicing headlights

• ‒ Remove radiator securing bolts and take out radiator to the front.

Vehicles with air conditioning system:

• ‒ Observe additional information and removal work => Page 19-15 .

Installing

Installation is carried out in the reverse order, when doing this note the following:

• ‒ Filling with coolant => Page 19-10
• ‒ Check headlight adjustment and adjust if necessary:

=> Maintenance

Additional information and removal work on vehicles with air conditioner

Note:

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 air cleaner.
• ‒ Remove air conditioner fluid reservoir and allow to hang free.
• ‒ Remove radiator securing bolts.
• ‒ Remove retaining clamp(s) from refrigerant pipes.
• ‒ Remove condenser from radiator and pull forward as far as is possible.
• ‒ Pull radiator out between condenser and lock carrier.