Radiator, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Hose Clip PliersVAS6362

Removal

Fig 1: Connectors And Clips

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-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Remove the air filter. Refer to AIR FILTER, REMOVING AND INSTALLING .

-- Remove the fan shroud: for vehicles built through 05.10 refer to FAN SHROUD, THROUGH 05/2010, REMOVING AND INSTALLING , for vehicles built from 06.10 refer to FAN SHROUD, VEHICLES FROM 06/2010, REMOVING AND INSTALLING .

Vehicles through 05/2010:

Fig 2: Clamps -1, 2 And 3-

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-- Remove the air duct hoses by loosening the hose clamps -1, 2 and 3-.

-- Free up the coolant hose on the front air duct in the center.

Fig 3: Charge Air Pressure Sensor -G31- with Intake Air Temperature Sensor -G42- -2-

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-- Disconnect the connector -2- on the Charge Air Pressure Sensor -G31-.

-- Loosen the clamp -1- and remove the air duct tube.

-- Remove the front air duct pipe in the center and the Intake Flap Motor 2 -V275-.

NOTE:

Ignore -item 3-.

-- Disconnect the connector -2-.

Fig 4: Clip -1-

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-- Lift the clips -1-, loosen the clamp -3- and -4- and remove the air duct hoses.

-- Remove the lower air duct pipe.

All Vehicles:

Fig 5: Identifying Coolant Hose From Radiator And Retaining Clip -Arrow-

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-- Disconnect the coolant hose from the radiator by raising the retaining clip -arrow-.

-- Remove left and right radiator locking mechanism by pressing down against clamps -arrow-.

Fig 6: Identifying Left And Right Radiator Locking Mechanism Pressing Down Against Clamps

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-- Remove the bolts -2- on the left and right sides of the lock carrier.

Fig 7: Bolts -2

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-- Disengage the cooler and move it toward the rear.

NOTE:

Ignore -item 1-.

-- Remove the bolt -2- from the back of the radiator.

Fig 8: Identifying Hydraulic Fluid Cooler Bolt -2- And Power Steering Cooler -1-

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-- Disengage power steering cooler -1- on climate control system condenser.

NOTE:

The hydraulic hose lines remain connected.

-- Remove the bolt -1- from the back of the radiator.

Fig 9: Identifying Screws On Rear Side Of Radiator

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-- Remove the clips -2- and -3-.

-- Remove ATF cooler -4- from radiator.

NOTE:

The ATF hose line remain connected.

-- Remove the bolt -3- on the back of the radiator.

Fig 10: Identifying A/C System Condenser, Retaining Clips And Screws

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-- Remove the clips -2- and -4-.

CAUTION:

There is a risk of damaging the condenser and refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the A/C condenser -1- from the cooler with the refrigerant lines still connected.

-- Remove the radiator downward.

Installation

Install in reverse order of removal. Note the following:

Tightening specifications. Refer to RADIATOR OVERVIEW .

NOTE:

If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS, INSTALLATION .

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before Installation.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

-- Connect the coolant hoses with the connector coupling, refer to Figure.

-- Install fan shroud. Refer to FAN SHROUD, THROUGH 05/2010, REMOVING AND INSTALLING .

-- Install the air filter. Refer to AIR FILTER, REMOVING AND INSTALLING .

-- Install the air duct pipes with the connector coupling, refer to Fig 11.

Fig 11: Identifying Clip In Release And Lock Positions

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-- Install the air duct hoses and screw-type clamps, refer to Fig 12.

Fig 12: Air Hose Clamp Identification

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-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING .

NOTE:

All of the coolant must be changed if the radiator was replaced.