Volkswagen Workshop Service and Repair Manuals

Removing and installing radiator and charge air cooler (Polo)   Note t  Radiator and charge air cooler are separate components. t  Radiator is mounted onto charge air cooler. t  Radiator and charge air cooler are removed and installed together. Assembly overview - parts of cooling system, body side → Chapter.

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Hose clip pliers -VAS 6340-

t	Torque wrench (5 … 50 Nm) -V.A.G 1331-

t	Guide rods -3411-

Removing –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Open spring-type clip -arrow- and pull coolant hose off.

–  Open spring-type clip -arrow- and pull coolant hose off.

–  Separate connector -arrow-.

–  Open hose guides at cowling -2- and push coolant hose -1- aside. –  Lift cowling out of brackets. –  Remove cowling downwards. –  Pull upper coolant hoses off radiator and charge air cooler. –  Pull connector off radiator outlet coolant temperature sender -G83-. –  Remove front bumper cover → General body repairs, exterior; Rep. gr.63

–  Unscrew securing bolts -arrows-. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50 –  Lift radiator out of lower mountings and press it back slightly. –  Remove side radiator mounting. –  Unscrew lateral securing bolt for AC compressor lines.

–  Remove securing bolts of condenser -arrows-. –  Secure condenser to lock carrier using cable ties. –  Remove radiator and charge air cooler downwards.

–  Pull radiator -1- in -direction of arrow- out of lateral charge air cooler -2- mounting brackets. Installing Installation is carried out in the reverse order. When installing, note the following: Filling with new coolant → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. Specified torques:

Component	Nm
Radiator mounting to lock carrier	5
Bracket for air conditioner compressor lines to radiator	5
Radiator to condenser	5