Audi Workshop Service and Repair Manuals

Removing and installing radiator with radiator cowl - Audi A4   Note Radiator and radiator cowl can only be removed and installed together as one unit. Special tools and workshop equipment required

t  Drip tray for workshop hoist -VAS 6208-

Removing –  Remove front noise insulation -1- → Rep. gr.66.

–  Remove impact bar → Rep. gr.63. –  Remove headlight (right-side) → Electrical system; Rep. gr.94. –  Remove charge air cooler → Chapter.

–  Remove headlight washer jet (right-side) (if applicable) → Electrical system; Rep. gr.92.

–  Unplug electrical connector -1- at crash sensor → Rep. gr.69.

–  Remove bolts -1- and -2-. –  Unclip mounting for headlight (right-side) -arrows- and remove.   Note Disregard -item 3-.

–  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 -arrows-. –  Detach air duct -1- from intermediate flange -2- for air cleaner housing.

–  Detach connections -1- and -2- from radiator (lift retaining clip).

–  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-. –  Remove condenser → Rep. gr.87. –  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 fan - exploded view“   Note If there are slight impressions on the fins, refer to → Chapter. –  Install condenser → Rep. gr.87. –  Attach air duct to intermediate flange for air cleaner housing → Rep. gr.23. –  Install headlight washer jet (right-side) → Electrical system; Rep. gr.92. –  Install charge air cooler → Chapter. –  Install headlight (right-side) → Electrical system; Rep. gr.94. –  Install impact bar → Rep. gr.63. –  Connect coolant hose with plug-in connector → Fig.. –  Fill up with coolant → Anchor.   Note The coolant in the entire system must be changed if the radiator is renewed.