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  Engine bung set -VAS 6122-

t  Drip tray for workshop hoist -VAS 6208- Removing   Note t  If there are slight impressions on the fins, refer to → Chapter. t  Collect drained coolant in a clean container for re-use or disposal.

–  Unclip cover caps. –  Unscrew nuts -arrows- and detach engine cover panel. Also pull out dipstick if necessary. –  Remove insulation beneath cover panel (if fitted).

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

–  Release quick-fasteners -1- and -2- and take off front noise insulation. Leave rear noise insulation in position. –  Remove bumper cover (front) → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.

–  Remove air duct in front of charge air cooler -arrows-.

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.

–  Place drip tray for workshop hoist -VAS 6208- under engine. Vehicles with coolant drain plug: –  Unscrew the drain plug -arrow- at coolant hose (bottom left) and drain off coolant.

Vehicles without coolant drain plug: –  Pull out retaining clip -1- for coolant temperature sender at radiator outlet -G83--item 2-. –  Pull coolant temperature sender at radiator outlet -G83- out of hose connection and drain off coolant.

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

–  Detach top coolant hose from radiator -arrow-.

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

Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.00. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Remove ATF pipes (top -arrow- and bottom) from radiator: → Rep. Gr.37. –  Tie ATF pipes up onto longitudinal member to prevent fluid escaping. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

Vehicles from 11.2004 onwards: –  Unplug electrical connectors (left and right) -3- for horns -2-.   Note Disregard -item 1-.

–  Remove bumper -arrows-.

All vehicles: –  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. –  Detach electrical connector -1- at high-pressure sender -G65-.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew securing bolts -arrows- for condenser.   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 forwards and lift off. Installing Installation is carried out in the reverse order; note the following: Vehicles from 11.2004 onwards: –  Install front bumper → Rep. Gr.63. All vehicles: –  Install lock carrier with attachments → Rep. Gr.50. –  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: –  Secure ATF lines → Rep. Gr.37. –  Check ATF level → Rep. Gr.37. Tightening torques

Component	Nm
Condenser to radiator	10
Air cowls to radiator	2