Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Drain coolant
• ‒ Pull coolant hoses off radiator.
• ‒ Pull connectors off thermo-switch and radiator fan.
• ‒ Removing front bumper:

=> General body repairs; Repair group 63; servicing bumper; removing and installing front bumper

• ‒ Remove headlights:

=> Electrical system; Repair group 94; servicing headlights

• ‒ Remove radiator securing bolts and take out radiator to the front.
• ‒ Remove V-belt from radiator fan and additional fan.
• ‒ Unbolt radiator fan and additional fan from lock carrier.

Vehicles with air conditioning system:

• ‒ Observe additional information and removal work => Page 19-17 .

Installing

Installation is carried out in the reverse order, when doing this note the following:

• ‒ Filling with coolant => Page 19-13
• ‒ Electrical connections and routing:

=> Electrical system; Repair group 97

• ‒ Check headlight adjustment and adjust if necessary:

=> Maintenance

Additional information and removal work on vehicles with air conditioner

Note:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

• ‒ Disconnect solenoid valve 1 (N80) with retaining ring from air cleaner lower part => Page 20-39 , removing and installing parts of the activated charcoal filter system.
• ‒ Remove air cleaner housing complete with air mass meter (G70).

=> Repair group 24; Motronic injection and ignition system; Servicing injection part

• ‒ Remove air conditioner fluid reservoir and allow to hang free.
• ‒ Remove retaining clamp(s) from refrigerant pipes.
• ‒ Remove condenser from radiator and pull forward as far as is possible.
• ‒ Pull radiator out between condenser and lock carrier.
• ‒ Secure condenser to body so that refrigerant pipes/hoses are not stressed.