Audi Workshop Service and Repair Manuals

Removing and installing radiator Special tools and workshop equipment required

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.   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.

–  Release quick-release fasteners -1-, unscrew bolts -2- and detach noise insulation. –  Remove bumper cover (front) → Rep. Gr.63.

–  Unplug electrical connector -3-.   Note Disregard items marked -1- and -2-.

–  Unplug electrical connectors -1 ... 3-. –  Remove bolts -arrows- on impact absorber for bumper. –  Detach impact absorber.

–  Remove air duct (right-side) -arrow- in front of auxiliary radiator.

–  Remove air duct (left-side) -arrow- in front of auxiliary radiator.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Unscrew drain plug -arrow- at thermostat housing and drain off coolant at engine.

–  Disconnect coolant hose (bottom) at radiator -arrow- and drain off remaining coolant.

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-.

–  Lift retaining clip -arrow- and disconnect coolant hose (top) from radiator.

–  Detach coolant hose for auxiliary radiator (right-side) -arrow- from radiator.

–  Unscrew bolts -arrows- at air ducts (left and right) at radiator.

–  Unscrew nuts -1 ... 5-. –  Move engine oil cooler with cooler for power steering to front (lines remain connected).

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 electrical connector -1- at high-pressure sender -G65-. –  Remove bolts -arrows-. –  Detach condenser and move to front (pipes/hoses remain connected).

–  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: –  Remove old O-ring -2- from coolant hose -3-. –  Lightly lubricate new O-ring with coolant and fit O-ring in coolant hose. –  Press coolant hose onto radiator -1- until it engages with a click. –  Press coolant hose in again and then pull to check that plug-in connector is correctly engaged. –  Install impact absorber for bumper → Rep. Gr.63. –  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 Tightening torques

Component	Nm
Condenser to radiator	9
Engine oil cooler to lock carrier	9
Power steering cooler to lock carrier	9