Radiator, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Old oil collecting and extracting device V.A.G 1782 (only for vehicles with automatic transmission)

Fig 2: Drip Tray For VAS 6100, VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray for workshop crane VAS 6208

Fig 3: Identifying Spring-Type Clip Pliers VAS 5024 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Spring-type clip pliers VAS 5024 A

Removing

NOTE:

Drained coolant must be stored in a clean container for disposal or reuse.

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Fig 4: Identifying Exhaust Pipe Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 5: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Bring lock carrier into service position → Lock carrier, moving into service position .

Fig 6: Opening/Closing Drain Plug From Lower Left Coolant Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
Open drain plug - arrow - from lower left coolant hose and drain coolant.

Fig 7: Disconnecting Lower Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect lower coolant hose from radiator - arrow -.

Fig 8: Disconnecting Coolant Hose At Upper Left Of Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose - 2 - at upper left of radiator.

NOTE:

Ignore - 1 -.

Fig 9: Removing Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.

Vehicles with automatic transmission:

Fig 10: Disconnecting ATF-Lines At Top And Bottom Of Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Observe the rules of cleanliness for working on automatic transmissions →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.

Place old oil collecting and extracting device V.A.G 1782 underneath.
Disconnect ATF-lines at top - arrow - and bottom of radiator →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Tie ATF lines up to longitudinal member to prevent fluid from escaping.

All:

Fig 11: Separating Left/Right Electrical Connectors Of Horns

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect left and right electrical connectors - 3 - of horns - 2 -

NOTE:

Ignore - 1 -.

Fig 12: Removing Bumper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bumper - arrows -.

Fig 13: Removing Left/Right Air Guides At Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left and right air guides at radiator - arrows -.

Fig 14: Identifying Outside Air Temperature Sensor G17, Bolts & High Pressure Sensor G65 Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip Outside Air Temperature Sensor G17 - 2 - from bracket.
Remove power steering cooling coil bolts - 3 - and - 4 - hydraulic hoses remain connected.
Pull off connector - 1 - from High Pressure Sensor G65.

CAUTION: The air conditioning refrigerant circuit must not be opened.

Remove bolts - arrows - for condenser.

NOTE:

Do not bend or stretch lines or hoses as A/C compressor and/or refrigerant lines/hoses may be damaged.

Pivot condenser downward with lines connected.

Fig 15: Releasing Both Radiator Retaining Pins And Removing By Pulling Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release both radiator retaining pins and remove by pulling upward - arrows -.
Pivot radiator forward, pull up and remove.

Installing

Installation is in reverse order of removal, note the following:

Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Fill with coolant → Cooling system, draining and filling .

NOTE:

Complete coolant must be replaced if the radiator was replaced.

Vehicles with automatic transmission:

Fasten ATF lines →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Check ATF level →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.

Torque specifications

Component	Nm
Condenser to lock carrier	6
Cooling coil for power steering to lock carrier	9