Radiator, removing and installing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and equipment

Fig 1: Identifying Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAG1306 Drip tray for VAG1202A

Removing

Remove front bumper:

Refer to

63 BUMPER
63 - BUMPERS for BODY EXTERIOR - CABRIOLET

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

WARNING:

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 2: Identifying Exhaust Pipe Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

Fig 3: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
Place VAG1306 drip tray beneath engine.

Vehicles with drain plug

Fig 4: Identifying Drain Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn radiator drain plug -2- counterclockwise. If needed, attach accessory hose to connection flange and drain coolant.

Vehicles without drain plug

Remove retaining clamp for Engine Coolant Temperature (ECT) sensor (on radiator) -G83-.
Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.

All

Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.

Fig 5: Disconnecting Lower Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect left coolant hose from radiator (arrow).

Fig 6: Removing Cover In Engine Compartment (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover -1- in engine compartment (left side).

Fig 7: Disconnecting Top Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect top coolant hose (arrow) from radiator.

Vehicles with automatic transmission

Fig 8: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover -1- in engine compartment (right side).

Fig 9: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts (arrows).
Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
Remove air guide -2-.

NOTE: Observe the rules of cleanliness for working on automatic transmissions:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

Place an oil receptacle underneath.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect top (arrow) and bottom ATF lines from radiator:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

Tie up ATF lines to top of longmember to prevent fluid from escaping.

All

Fig 11: Removing Air Ducts On Left/Right Of Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air guides from left and right of radiator (arrows).

Fig 12: Identifying Outside Air Temperature Sensor G17, Bolts & High Pressure Sensor G65 Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip temperature sensor -2- for outside temperature display from bracket.
Remove bolts -3- and -4- and remove power steering cooling coil. Hoses remain connected.
Disconnect harness connector -1- at High pressure sensor -G65-.

CAUTION:

Do not open refrigerant circuit for A/C system.

Remove condenser mounting bolts (arrows).

NOTE: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

Carefully swing condenser downward and move aside.

Fig 13: Locating Both Radiator Retaining Bolts, Pulling Up And Removing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen both radiator retaining bolts, pull up and remove (arrows).
Tilt radiator forward, pull up and remove.

Installing

Installation is reverse of removal, noting the following:

Install front bumper:

Refer to

63 BUMPER
63 - BUMPERS for BODY EXTERIOR - CABRIOLET

Top up coolant. Refer to Filling .

NOTE: Complete quantity of coolant must be replaced if the radiator was replaced.

Vehicles with automatic transmission

Secure ATF lines:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Check ATF level:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

Tightening torque

Component	Nm
Condenser to radiator	10