Audi Workshop Service and Repair Manuals

Removing and installing radiator Special tools and workshop equipment required

t  Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-

t  Hose clip pliers -V.A.G 1921- Removing   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Unscrew securing bolts for radiator cowl which are accessible from above.

–  On vehicles with automatic headlight range control detach bracket for headlight range control sender at top of wheel housing (left-side) -arrows-.

–  Remove noise insulation panels (centre, left and right) -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- or -V.A.G 1306- under engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. –  Pull off retaining clip for bottom coolant hose and detach coolant hose -2- from radiator.

–  Also disconnect coolant hose at bottom of oil cooler -arrow-, and drain off remaining coolant.

–  Detach both connectors -arrows- for radiator fan at bottom left of radiator cowl. –  Unscrew radiator cowl bolts accessible from below. –  Remove the radiator cowl with both fans from below.

–  Unplug electrical connector -2- from coolant temperature sender - radiator outlet -G83-.   WARNING The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Detach refrigerant line -1- at radiator.

–  Remove upper coolant hose -1- at radiator. –  Remove front bumper → Rep. Gr.63. –  Remove the left and right-hand air ducts from the radiator.   WARNING The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Unscrew securing bolts -1- for the condenser. –  Remove bolts -2- at radiator. –  Tie up condenser to lock carrier with wire. –  Swivel radiator slightly to the rear and take it out from below.

Installing Installation is carried out in the reverse order; note the following: –  Fit mountings -3- and -4- on radiator as illustrated. –  Have second mechanic fit radiator bolts. –  Install front bumper → Rep. Gr.63. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Radiator to mounting	5
Condenser to radiator	5
Refrigerant line to radiator	5
Bracket for headlight range control sender to body	6
Radiator cowl to radiator	5