Radiator, removing and installing

WARNING: This page is about a different car, the 2006 Audi A8, 2005 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Hose Clamp Pliers V.A.G 1921

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hose clamp pliers V.A.G 1921

Fig 2: Drip Tray For VAS 6100, VAS 6208

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Drip tray for workshop crane VAS 6208

Removing

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

Open cap of coolant expansion tank.

Fig 3: Removing Bolts For Exhaust Pipe Of Parking Heater/Auxiliary Heater On Noise Insulation

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

Fig 4: Locating Mounting Parts And Removing Noise Insulation

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Remove front sound insulation by loosening fasteners - 1 -.

NOTE:

Ignore - 2, 3, 4 -.

Remove front part of wheel housing liner at left and right front → 66 - EXTERIOR EQUIPMENT .
Remove front bumper cover → 63 - BUMPERS .
Place drip tray for workshop crane VAS 6208 under engine.

Fig 5: Disconnecting Lower Right Coolant Hose From Radiator

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Disconnect lower right coolant hose from radiator - arrow - and drain coolant.

Fig 6: Disconnecting Lower Left Coolant Hose From Radiator

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Disconnect lower left coolant hose from radiator - arrow -.

Fig 7: Removing Left Coolant Hose In Center Of Radiator

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If present, remove left coolant hose in center of radiator - arrow -.

Fig 8: Disconnecting Upper Right Coolant Hose From Radiator

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Disconnect upper right coolant hose from radiator - arrow -.

Fig 9: Identifying Outside Air Temperature Sensor G17 & Electrical Connectors

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Remove Outside Air Temperature Sensor G17 - 4 -.
Disconnect electrical connectors - 1, 2, 3 -.
Free up wiring harness.
On a vehicle with distance regulation, disconnect electrical connector on Distance Regulation Control Module J428 - 5 -.

Fig 10: Uncliping Electrical Harness Connectors From Braces

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Unclip electrical harness connectors - 1 - and - 2 - from braces.

Fig 11: Removing Bolts And Bumper With Braces

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Remove bolts - arrows - and remove bumper with braces.

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

NOTE:

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

Remove bolts - arrows -.
Swivel condenser with power steering cooler downward and tie up to engine.

Fig 12: Removing Both Brackets For Radiator

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Remove both brackets for radiator - arrows -.
Move radiator slightly toward front at top and lift out of lock carrier.

Installing

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

NOTE:

Converting to radiator with bypass → Converting to radiator with bypass .
Secure all hose connections using hose clamps appropriate for the model type .

Install front bumper cover → 63 - BUMPERS .
Install front part of wheel housing liner at front left and right → 66 - EXTERIOR EQUIPMENT .
Fill with coolant → Cooling system, draining and filling .

NOTE:

Complete coolant must be replaced if the radiator was replaced.

Torque specifications

Component	Nm
Radiator bracket to lock carrier	6
Condenser to lock carrier	6
Braces to lock carrier	9