Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ T10007 Refractometer
• ◆ V.A.G 1306 Drip tray
• ◆ V.A.G 1331 Torque wrench (5 ... 50 Nm)
• ◆ VAS 5024 Assembly tool for spring-type clips

Removing

• ‒ Remove centre as well as the left and right-hand sound insulation:

=> General body repairs exterior; Repair group 50; Noise insulation - overview

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

=> General body repairs, exterior; Repair group 63; Front bumper; Removing and installing front bumper

• ‒ Bring lock carrier into service position:

=> General body repairs, exterior; Repair group 50; Body, front; Lock carrier service position

• ‒ Pull coolant hoses quick release couplings off radiator.
• ‒ Remove radiator securing bolts and take radiator with fan out downwards.

Models with an air conditioning system:

• ‒ Observe additional information and removal work .

Installing

Installation is performed in reverse order to removal, considering the following:

• ‒ Electrical connections and routing:

=> Current flow diagrams, Electrical fault finding and Fitting locations

• ‒ Replenishing coolant => page 19-12.

Additional information and assembly work on models with an air conditioning system

Note:

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

• ‒ Remove retaining clamp(s) from refrigerant lines.
• ‒ Remover radiator securing bolts from side of radiatr.

• ‒ Remove condenser from radiator.
• ‒ Secure condenser to body, so that the refrigerant lines/hoses are not undr stress.
• ‒ Swing radiator out downwars.