Volkswagen Workshop Service and Repair Manuals

Removing and installing radiator

Special tools and workshop equipment required

t	Cooling system tester adapter -V.A.G 1274/8-

t	Drip tray -VAS 6208-

t	Hose clip pliers -VAS 6362-

t	Cooling system filler unit -VAS 6096-

t	Refractometer -T10007-

Removing radiator: –  Remove radiator fan -V7- and radiator fan 2 -V177- → Chapter. –  Drain coolant → Chapter. –  Remove front bumper → General body repairs, exterior; Rep. Gr.63. –  Pull coolant hoses off radiator.   Caution To prevent damage to condenser and to refrigerant lines, ensure that lines are not stretched, kinked or bent.

–  Remove bolts -arrows- from radiator mount.

–  Unscrew lower securing bolts -arrows- for condenser.

–  Swing radiator and condenser back slightly and lift out of lower supports. When doing this, pull lock carrier on left support -1- down slightly.

–  Unscrew securing bolt for refrigerant lines on right side of radiator -arrow-.

–  Unscrew upper securing bolts -arrows- for condenser. –  Remove radiator upwards. Installing –  Install radiator from above and bolt to condenser. –  Insert radiator and condenser into lower supports.

–  Position upper radiator mount onto radiator and bolt to lock carrier -arrows-. –  Install front bumper → General body repairs, exterior; Rep. Gr.63. –  Install radiator fan -V7- and radiator fan 2 -V177- → Chapter. –  Fill with coolant → Chapter. Torque settings

Component	Nm
Radiator mounting to lock carrier	5
Condenser to radiator	5
Cowling to radiator	5