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 front bumper → Rep. Gr.63.   Note t  Collect drained coolant in a clean container for re-use or disposal. t  The coolant must be drained off completely if the radiator is renewed.   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.

–  Remove noise insulation -arrows-.

–  Remove air intake hose going to charge air cooler (right-side) -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect coolant hose (bottom right) -2- at radiator and drain off coolant.   Note Disregard -item 1-.

–  Detach top left coolant hose from radiator -arrow-.

–  Remove cover -1- at right of engine compartment. –  Unscrew bolts -2- and detach air duct from air cleaner housing -3-.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Detach gear oil pipes (top -arrow- and bottom) from radiator → Rep. Gr.34. –  Tie gear oil pipes up onto longitudinal member to prevent fluid escaping.

–  Move electrical wiring harness on air duct (left and right) clear to one side. –  Remove air duct -1- in front of charge air coolers (left and right).

–  Unbolt pressurising fan and cooling pipe for hydraulic fluid for power steering -arrows-.   WARNING The air conditioner refrigerant circuit must not be opened.   Note

To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Unbolt air ducts (left and right) at radiator -1-. –  Remove bolts -2- and -3- at condenser. –  Unplug electrical connector at air conditioner pressure switch -F129-. –  Pull condenser upwards and out of bracket. –  Move condenser to side and tie onto right front wheel with wire.

–  Release two retaining pins for radiator and pull out upwards -arrows-. –  Swivel radiator forwards by its top edge and remove upwards. Installing Installation is carried out in the reverse order; note the following:   Note t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install front bumper → Rep. Gr.63. –  Fill cooling system → Anchor. –  Secure gear oil pipes to gear oil cooler → Rep. Gr.34. –  Check gear oil level in manual gearbox → Rep. Gr.34. Tightening torques

Component	Nm
Condenser to radiator	5
Cooling pipe to radiator	5
Pressurising fan to radiator	5
Gear oil pipe to radiator	5