Audi Workshop Service and Repair Manuals

Removing and installing radiator Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782-

t  Drip tray for workshop hoist -VAS 6208- Removing –  Remove bumper cover (front) → Rep. Gr.63.   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 on coolant expansion tank.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release bolts or quick-release fasteners -1- and -2- and take off front noise insulation.

–  Place drip tray for workshop hoist -VAS 6208- under engine. Vehicles with drain plug: –  Turn drain plug -2- on radiator anti-clockwise and drain coolant (attach hose to connection if necessary). Vehicles without drain plug: –  Pull out retaining clip and remove radiator outlet coolant temperature sender -G83--item 3-. –  Pull radiator outlet coolant temperature sender -G83- out of hose connection and drain off coolant. All vehicles: –  Disconnect coolant hose from radiator by pulling off retaining clip -1- at bottom.

–  Disconnect coolant hose (left-side) from radiator -arrow-.

–  Remove cover -1- on left side of engine compartment.

–  Disconnect coolant hose (top) -arrow- from radiator.

Vehicles with multitronic gearbox 01J or automatic gearbox 01V: –  Remove cover -1- at right of engine compartment.

–  Remove bolts -arrows-. –  Disengage activated charcoal filter solenoid valve 1 -N80--item 1- at air duct. –  Remove air duct -2-.   Note

Observe rules for cleanliness when working on gearbox → Rep. Gr.00 or → Rep. Gr.37. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Detach ATF pipes (top -arrow- and bottom) from radiator: → Rep. Gr.37. –  Tie ATF pipes up onto longitudinal member to prevent fluid escaping.

All vehicles: –  Unbolt left and right air guides from radiator -arrows-.

–  Unclip ambient temperature sensor -G17--item 2- from bracket. –  Unscrew bolts -3- and -4- for power steering cooling pipe; the hydraulic hoses remain attached. –  Detach electrical connector -1- at high-pressure sender -G65-.   WARNING The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Pivot condenser downwards with pipes/hoses attached.

–  Release two retaining pins for radiator and pull out upwards -arrows-. –  Swivel radiator slightly to the front and lift it out. Installing Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. Vehicles with multitronic gearbox 01J or automatic gearbox 01V: –  Install ATF pipes → Rep. Gr.37. All vehicles: –  Install bumper cover (front) → Rep. Gr.63. –  Fill cooling system → Anchor.   Note The coolant in the entire system must be changed if the radiator is renewed. Vehicles with multitronic gearbox 01J or automatic gearbox 01V: –  Check ATF level → Rep. Gr.37. Tightening torques

Component	Nm
Condenser to lock carrier	10
Power steering cooling pipe to lock carrier	9