Removal And Installation: Radiator

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Hose Clip Pliers V.A.G 1921
Drip Tray VAS 6208

Removing

NOTE:

When assembled correctly, radiator and condenser can show slight impressions on fins. This is not damage. Radiators or condensers should not be replaced because of slight impressions like these.

WARNING:

Risk of scalding due to hot steam and hot coolant.

When the engine is warm the cooling system is under pressure.
Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

-- Open coolant reservoir cap.

-- Remove fan shroud. Refer to FAN SHROUD .

-- Disconnect electrical connector -1- on engine coolant temperature (ECT) sensor (on radiator) -G83-.

Fig 1: Disconnect Electrical Connector -1-

Courtesy of AUDI OF AMERICA, LLC

-- Place VAS 6208 under engine.

-- Remove coolant hose downward from radiator -arrow- and allow coolant to drain.

-- Remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow coolant to drain.

Fig 2: After-Run Coolant Pump -V51

Courtesy of AUDI OF AMERICA, LLC

-- Remove front bumper cover. Refer to Description and Operation .

-- Remove upper coolant hose -arrow- from radiator by removing retaining clip.

Fig 3: Remove Upper Coolant Hose

Courtesy of AUDI OF AMERICA, LLC

-- Remove bolts -arrows- by releasing left and right air ducts and pressing to side.

Fig 4: Air Cooler Lower Mounting Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Tip radiator back slightly at upper edge.

-- Disengage radiator from lower mounting points by raising radiator.

-- Slide radiator in direction of engine.

-- To prevent radiator from sinking down, support it from below.

Fig 5: Charge Air Cooler Bolts

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury from refrigerant.

The air conditioning refrigerant circuit must not be opened.

CAUTION:

Risk of damage to condensor and refrigerant lines and hoses.

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

-- Remove bolts -arrows-.

-- Remove condenser from radiator.

-- Place condenser forward in lock carrier and secure against falling down with cable ties.

-- Remove radiator downward.

Installing

Tightening specifications, refer to RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

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

-- Install fan shroud, refer to FAN SHROUD .

-- Install condenser. Refer to CONDENSER .

-- Install front bumper. Refer to Description and Operation .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .