Radiator, removing and installing

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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

Removing

NOTE:

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

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 2: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.

Fig 3: Removing Right Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove right air guide - arrow - in front of auxiliary cooler.

Fig 4: Removing Left Air Guide In Front Of Auxiliary Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left air guide - arrow - in front of auxiliary cooler.

Fig 5: Removing Drain Plug On Coolant Thermostat Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray for workshop crane VAS 6208 under engine.
Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.

Fig 6: Disconnecting Lower Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 7: Removing Cover In Engine Compartment (Right Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 8: Identifying Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - item 1 - from air guide.
Remove bolts - arrows -.
Remove air duct - 2 -.

Fig 9: Disconnecting Top Coolant Hose From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect top coolant hose - arrow - from radiator.

Fig 10: Removing Bolts On Left/Right Air Guides At Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - on left and right air guides at cooler.

Fig 11: Removing Power Steering Hydraulic Oil Cooling Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip Outside Air Temperature Sensor G17 - 1 - from bracket and free up wire.
Remove power steering hydraulic oil cooling pipe - arrows - ; do not open hydraulic oil circuit.
Tie up power steering hydraulic oil cooling pipe to side.

Fig 12: Removing Coolant Fan Control (FC) Control Module J293 From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove Coolant Fan Control (FC) Control Module J293 from radiator - arrow -.

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

NOTE:

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

Fig 13: Disconnecting Electrical Harness Connector At High Pressure Sensor G65

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - at High Pressure Sensor G65.
Remove bolts - arrows -.
Remove condenser and swing downward with lines connected.

Fig 14: 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 -.
Tilt radiator at upper edge forward, pull up and remove.

Installing

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

Install the front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Fill with coolant Filling .

NOTE:

Complete coolant must be replaced if the radiator was replaced.

Torque specifications

Component	Nm
Condenser to radiator	10
Cooling coil to radiator	10
Coolant Fan Control (FC)Control Module J293 to radiator	10
Drain plug to coolant regulator housing	25