Radiator, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Drip Tray For VAS 6100, VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray for workshop crane VAS 6208

Fig 2: 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

Removing

Fig 3: Identifying Front Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove front engine cover - arrows -.

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 4: Locating Fasteners Exhaust Pipe

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. Rear section of noise insulation remains installed.
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Place drip tray for workshop crane VAS 6208 under engine.

Fig 6: Disconnecting Coolant Hose From Lower Left Of Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose - arrow - from lower left of radiator and drain coolant.

Fig 7: Disconnecting Lower Right Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose from lower right of radiator - arrow -.

Fig 8: Disconnecting Top Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect top coolant hose - right arrow - from radiator.

NOTE:

Ignore - left arrow -.

Vehicles with automatic transmission:

Fig 9: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

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

Place old oil collecting and extracting device V.A.G 1782 under engine.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove upper and lower ATF lines - arrow - on cooler →
- 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: Disconnecting 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 Cross Member For Bumper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cross member for 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.
Disconnect electrical harness connector - 1 - at High Pressure Sensor G65.

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

Remove bolts - arrows -.

NOTE:

To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

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:

NOTE:

Secure all hose connections using hose clamps appropriate for the model type .

Install 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
.
Install front bumper cross member →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
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 radiator was replaced.

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 condenser	9