Audi Workshop Service and Repair Manuals

Removing and installing radiator Special tools and workshop equipment required

t  Removal lever -80 - 200-

t  Hose clip pliers -V.A.G 1921-

t  Drip tray for workshop hoist -VAS 6208- Removing –  Remove bonnet → Chapter.   Note

Collect drained coolant in a clean container for re-use or disposal.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap -arrow- on coolant expansion tank.

–  Remove noise insulation -arrows-. –  Remove bumper cover (front) → Rep. Gr.63.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect coolant hose (bottom) at radiator -arrow- and drain off coolant.   Note Disregard -item 1-.

–  Remove bottom air intake hose from charge air cooler -arrow-.

–  Remove bolts -1 and 4- securing radiator at bottom of radiator cowl.

Vehicles with engine code letters AMF, BHC: –  Unplug electrical connector -1- at intake manifold pressure sender -G71- and move wiring clear. All models: –  Remove air intake hose -2- from charge air cooler.

–  Detach top left coolant hose from radiator -item 2-.   Note Disregard -item 1-.

–  Remove bolts -2 and 3- securing radiator at top of radiator cowl.

–  Unplug electrical connector at horn. –  Remove two bolts each on left and right -3- and detach reinforcement rail. –  Lever off circlips -2-. –  Remove bolts on left and right -1- and detach bumper impact absorber.

–  Detach electrical connector -1- at high-pressure sender -G65-. –  Cut through cable tie -2-.

–  Detach ambient temperature sensor -G17--arrow- from bracket.

–  Use removal lever -80 - 200- to press off electrical wiring harness leading to high-pressure sender -G65- and ambient temperature sensor -G17- from air duct (left-side).

–  Unbolt air ducts from lock carrier -arrows-.

Caution The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for condenser.   Note To prevent damage to the refrigerant lines and hoses, ensure that the pipes and hoses are not stretched, kinked or bent when working on the condenser.

–  Pivot condenser slightly forward on right side of vehicle -arrow 1-. –  Press radiator with charge air cooler to left side of vehicle as far as possible -arrow 2-. –  Spray rubber grommets on mounting for charge air cooler with silicone-free lubricant. –  Disengage retaining pegs of charge air cooler from rubber grommets on radiator cowl (press eyelets of radiator cowl slightly to right -arrow 3-). –  Carefully pull condenser forward as far as possible on left side (connection side). –  Guide radiator connections out of radiator cowl one by one, moving radiator up or down as required. –  Take out radiator with charge air cooler to left.

–  Remove a total of 4 bolts securing charge air cooler to radiator -arrows-. Installing Installation is carried out in the reverse order; note the following: –  Install impact absorber and reinforcement rail → Rep. Gr.63. –  Install bumper cover (front) → Rep. Gr.63. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Charge air cooler to radiator	6
Radiator to radiator cowl	6
Condenser to radiator cowl	6
Air ducts to radiator cowl	1.5