Removal And Installation: Radiator

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Refractometer T10007
Drip tray V.A.G 1306 or drip tray for workshop crane VAS 6208
Torque wrench V.A.G 1331
Spring-type clip pliers VAS 5024A
AdapterV.A.G 1274/8
Cooling system charge unit VAS 6096

Removing

WARNING:

Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.

NOTE:

When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work.

Hoses are secured with spring-type clips. When performing repairs, use new spring-type clips.

Pliers for spring clamps VAS 5024A or Hose clamp pliers V.A.G 1921 are recommended for installing spring clamps.

When installing coolant hoses, make sure they are free of stress and do not come into contact with other components (observe markings on coolant connections and hoses).

Always replace gaskets and seals.

Arrows on coolant pipes and coolant hoses must line up across from each other.

Perform cooling system leakage test with cooling system tester V.A.G 1274 and the adapter V.A.G 1274/8 and adapter V.A.G 1274/9.

-- Drain the coolant COOLING SYSTEM, DRAINING AND FILLING .

-- Remove the fan support with the coolant fans COOLANT FANS .

-- Unscrew air guide on lock carrier -arrows-.

Fig 1: Removing Air Duct At Lock Carrier

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the coolant connection at upper radiator (quick-release coupling).

-- Remove the left air duct hose, by lifting the retaining clips -arrows- slightly.

Fig 2: Identifying Left Air Duct Hose And Retaining Clips

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove bolts -arrows- from radiator.

Fig 3: Identifying Radiator Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove radiator downward. Push the radiator slightly upward and then lower it downward in order to get by the charge air cooler connection.

Installing

Installation is performed in reverse order. When doing this note the following:

Replace coolant if a new radiator was installed.
Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

Tightening Specifications

Component	Nm
Radiator to charge air cooler	5
Fan mount to radiator	5