Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ V.A.G 1306 Drip tray
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1921 Pliers for spring-type clips or VAS 5024 assembly tool for spring-type clips
• ◆ Anti-freeze tester

Removing

• ‒ Remove front bumper cover and bumper carrier:

=> General body repairs, exterior; Repair group 63; Front bumper; Assembly overview

• ‒ Drain coolant .
• ‒ Pull coolant hoses off radiator.
• ‒ Pull connectors off thermo-switch.
• ‒ Remove radiator securing bolts and take out radiator downwards.

Vehicles with air conditioning system:

• ‒ Observe additional information and removal work => Page 19-16 .

Installing

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

• ‒ Filling with coolant => Page 19-10
• ‒ Electrical connections and routing:

=> Current flow diagrams, Electrical fault finding and Fitting locations

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 retaining clamp(s) from refrigerant pipes.
• ‒ Unbolt condenser from radiator and secure to lock carrier.
• ‒ Pull radiator out carefully, downwards.