Volkswagen Workshop Service and Repair Manuals

Removing and installing radiator

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

t	Cooling system charge unit -VAS 6096-

t	Adapter for cooling system tester -V.A.G 1274/8-

t  Refractometer -T10007 A- Removing –  Removing and installing front bumper → General body repairs, exterior; Rep. gr.63.   WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. –  Drain coolant → Chapter.

–  Disconnect connector -2- from wiring harness -1- of radiator fan -2-. –  To do this, unlock locking tab -arrow A-. –  Disconnect connector -2- in -direction of arrow B-.

Vehicles with radiator fan thermal switch -F18- –  Unlock and disconnect connector -1- from radiator fan thermal switch -F18-.

Continuation for all vehicles –  Unlock locking tab -1- on filler neck of washer fluid reservoir in -direction of arrow A-. –  Pull filler neck -1- of washer fluid reservoir off in -direction of arrow B-.

–  Loosen clamps -arrows- and disconnect coolant hoses -1- at top of radiator. –  Pull connectors off thermal switch and radiator fan. –  Remove front left headlights → Electrical system; Rep. gr.94 Vehicles with air conditioner   Note To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent. –  Remove condenser → Heating, air conditioning; Rep. gr.87.

Continuation for all vehicles –  Unlock retainers -2- on left and right side by pushing locking tab -1- in -direction of arrow- using a screwdriver.

–  Tilt radiator -1- in -direction of arrow A-. –  Pull right side of radiator -1- upwards in -direction of arrow B-. –  Tilt radiator -1- further forwards in -direction of arrow A- to release it from lock carrier. –  Pull radiator -1- out of bottom mountings in -direction of arrow C-. If the radiator is to be renewed: –  Remove radiator cowl with radiator fan → Chapter. –  Remove radiator fan thermal switch -F18- → Chapter. Installing Install in reverse order. In the process, note the following: Vehicles with air conditioner   Note To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent. –  Install condenser → Heating, air conditioning; Rep. gr.87. –  Replenish coolant → Chapter. –  Observe electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install front bumper → General body repairs, exterior; Rep. gr.63.