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  Used oil collection and extraction unit -V.A.G 1782- for vehicles with multitronic gearbox 0AW/automatic gearbox 0B6

t  Engine bung set -VAS 6122- for vehicles with multitronic gearbox 0AW/automatic gearbox 0B6

t  Drip tray for workshop hoist -VAS 6208-

Removing   Note If there are slight impressions on the fins, refer to → Chapter. –  Remove front noise insulation -1- → Rep. Gr.66.

–  Remove bumper cover (front) and bumper → Rep. Gr.63. –  Remove headlight (right-side) → Rep. Gr.94.

–  Remove washer jet (right-side) for headlight washer system (if applicable) → 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).

–  Detach connection -arrow- from radiator (lift retaining clip).

–  Unplug electrical connector -1- and, if fitted, -2- for radiator fan (push retainer to the rear -arrow- and press down release catch).

Vehicles with multitronic gearbox 0AW/automatic gearbox 0B6: –  Position used oil collection and extraction unit -V.A.G 1782- below connection point.   Note Observe rules for cleanliness when working on gearbox → Rep. Gr.00. –  Unscrew bolts -arrows- and detach ATF pipes from radiator.   Note 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-.

All vehicles (continued): –  Lift retaining clips -1- and -2- and detach connection from radiator.

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

–  If fitted, release retaining clips -arrow A- and swivel power steering cooling pipe -1- to front -arrow B-. –  Lift power steering cooling pipe away from condenser and place onto engine.

–  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 l  Tightening torque → Chapter. Installation is carried out in the reverse order; note the following: –  Attach air duct to intermediate flange for air cleaner housing → Rep. Gr.24. –  Vehicles with multitronic gearbox 0AW/automatic gearbox 0B6: install ATF pipes → Rep. Gr.37. –  Install bumper and bumper cover (front) → 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. –  Vehicles with multitronic gearbox 0AW/automatic gearbox 0B6: check ATF level → Rep. Gr.37.