Audi Workshop Service and Repair Manuals

Removing and installing radiator with radiator cowl   Note Radiator and radiator cowl can only be removed and installed together as one unit. Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782- (for vehicles with dual clutch gearbox)

t  Engine bung set -VAS 6122- for vehicles with dual clutch gearbox

t  Drip tray for workshop hoist -VAS 6208- Removing   Note If there are slight impressions on the fins, refer to → Chapter. –  Remove noise insulation → Rep. gr.66. –  Remove bumper cover (front) and bumper → Rep. gr.63. –  Remove charge air cooler → Chapter. A4 vehicles –  Remove headlight (right-side) → Rep. gr.94. –  Remove headlight washer jet (right-side) (if applicable) → Rep. gr.92.

–  Unplug electrical connector -1- at front airbag crash sensor for front passenger side -G284- → Rep. gr.69.

–  Remove bolts -1- and -2-. –  Unclip mounting for headlight (right-side) -arrows- and remove. All vehicles

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Remove drain plug -1- and drain off coolant. –  Then disconnect coolant hose -2- from radiator (pull out retaining clip).

WARNING Risk of injury as the radiator fans may start up automatically. Unplug electrical connectors before starting to work in the area of radiator cowl. –  Take electrical connector -1- for radiator fan out of bracket and unplug connector (push retainer to the rear -arrow- and press down release catch).

–  Remove bolts -1, 2, 3, 5-. –  Lift cover -4- above lock carrier and detach from radiator grille -arrow-.

–  Remove bolts -arrows-.

–  Detach connections -1- and -2- from radiator (lift retaining clip). –  Remove air duct -1- and intermediate flange -2-.

Vehicles with multitronic gearbox: –  Position used oil collection and extraction unit -V.A.G 1782- below connection point.   Note Observe rules for cleanliness when working on multitronic gearbox → Rep. gr.00. –  Unscrew bolts -arrows- and detach ATF lines from radiator.   Note t  Tie ATF lines up onto longitudinal member to prevent fluid escaping. t  To prevent dirt from entering, seal off open pipes/lines and connections with a clean plug from engine bung set -VAS 6122-. All vehicles

–  Release catches -arrows A- and detach air duct -1- on left and right -arrow B-.

–  Release retaining pins for radiator on both sides and pull out upwards -arrows-.

–  Remove bolts -1- on both sides and detach radiator bracket with radiator from lock carrier -arrow-. –  Slightly lower radiator.

–  Have a 2nd mechanic release retaining clips -1- in direction of -arrow A- and lift condenser -2- out of mounts on radiator -arrows B-.   Caution Make sure that condenser and refrigerant pipes and hoses are not damaged. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Pivot condenser forwards with pipes/hoses attached. –  Detach radiator.

–  Press locking tabs on left and right sides of radiator cowl -arrow- and at the same time lift radiator cowl off radiator. Installing Installation is carried out in the reverse order; note the following: l  Tightening torque → Chapter „Radiator and radiator fans - exploded view“ –  Attach air duct to intermediate flange for air cleaner housing → Rep. gr.24. –  On vehicles with multitronic gearbox: secure ATF lines → Rep. gr.37. –  Install charge air cooler → Chapter. –  Install bumper and bumper cover (front) → Rep. gr.63. –  Connect coolant hose with plug-in connector to coolant pipe → Fig.. –  Fill up with coolant → Chapter.   Note The coolant in the entire system must be changed if the radiator is renewed. –  On vehicles with multitronic gearbox: check ATF level → Rep. gr.37.