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  Collect drained coolant in a clean container for re-use or disposal. t  Even when the radiator and condenser are correctly installed, slight impressions may be visible on the fins of these components. This does not mean that the components are damaged. If the fins are only very slightly distorted, this does not justify renewal of the radiator or the condenser.   WARNING Hot steam/hot coolant may escape when opening expansion tank; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank.

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

–  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 cover -1- at right of engine compartment.

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

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

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

–  Unclip ambient temperature sensor -G17--item 1- from bracket and move wiring clear. –  Detach cooling pipe for power steering hydraulic fluid -arrows-; do not open hydraulic fluid circuit. –  Tie up cooling pipe for power steering hydraulic fluid to side.

–  Unbolt radiator fan control unit -J293- from radiator -arrow-.   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 pivot downwards (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: –  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	10
Cooling pipe to radiator	10
Radiator fan control unit -J293- to radiator	10
Drain plug to thermostat housing	25