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- (only for vehicles with automatic gearbox)

t  Drip tray for workshop hoist -VAS 6208-

t  Spring type clip pliers -VAS 5024 A- Removing   Note Collect drained coolant in a clean container for re-use or disposal.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank 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 quick-release fasteners -1- and -2- and take off front noise insulation. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier to service position → Chapter.

–  Place drip tray for workshop hoist -VAS 6208- or drip tray -V.A.G 1306- under engine. –  Unscrew the drain plug -arrow- at coolant hose (bottom left) and drain off coolant.

–  Detach coolant hose (bottom) from radiator -arrow-.

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

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-. Vehicles with automatic gearbox:   Note

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

All vehicles: –  Unplug electrical connectors (left and right) -3- for horns -2-.   Note Disregard -item 1-.

–  Remove bumper -arrows-.

–  Unbolt air cowls (left and right) at 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. –  Unplug connector -1- from high-pressure sender -G65-.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew securing bolts -arrows- for condenser.   Note To prevent damage to the air conditioner compressor and refrigerant pipes/hoses, 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 forwards and lift off. Installing Installation is carried out in the reverse order; note the following: –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Fill up with coolant → Chapter.   Note The coolant in the entire system must be changed if the radiator is renewed. Vehicles with automatic gearbox: –  Secure ATF lines → Rep. Gr.37. –  Check ATF level → Rep. Gr.37. Tightening torques

Component	Nm
Condenser to lock carrier	6
Power steering cooling pipe to lock carrier	9