Radiator: Service and Repair

Radiator Removing and Installing




Special tools and equipment
^ VAG1306 Drip tray for VAG1202A
^ VAG1331 Torque wrench: 5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG1921 Hose clip pliers
^ Anti-freeze tester

Note:
Refer to "Cooling System Component, Body Side" diagram and "Removal" and "Installation" information during procedures.




Cooling System Components, Body Side
1. Radiator
2. O-ring - Always replace
3. Coolant hose, upper
4. Retaining clip - Make sure it is securely seated
5. Engine Coolant Temperature (ECT) sensor -G62
6. Bolt. Tighten to: 4 Nm (35 inch lbs.)
7. Cap
Test pressure 1.4 to 1.6 bar (20 to 23 psi)
8. Bolt. Tighten to: 2 Nm (18 inch lbs.)
9. Coolant expansion tank
10. Connector
11. To cylinder head
12. Air ducting
13. Bolt 10 Nm (7 ft. lbs.)
14. Additional fan - Optional equipment
15. Fan ring - For auxiliary fan
16. Retaining clip - Make sure it is seated securely
17. Fan ring
18. Coolant fan
19. Bracket - For coolant fan connector
20. Coolant hose, lower - Attached to radiator with clip
21. Coolant fan control thermal switch -F18- For electric fan
Tighten to: 35 Nm (26 ft. lbs.)
Switching temperatures:
Stage 1 ON: 92 to 97°C OFF: 84 to 91°C
Stage 2 ON: 99 to 105°C OFF: 91 to 98°C
22. Bracket For radiator
23. Bracket For radiator - Note installation position

Removing
- Drain coolant. Service and Repair
- Remove front panel: [1][2]Procedures
- Disconnect coolant hoses from radiator.
- Disconnect connectors from thermo-switch.
- Remove ribbed belt tensioner.
- Remove radiator mounting bolts and take out radiator.

Note: Vehicles with A/C:

Warning

Do not open the A/C refrigerant circuit.

Note: To prevent damage to the condenser and to the refrigerant lines/hoses, make sure that the lines and hoses are not stretched, kinked or bent.

- Remove retaining clamp(s) from refrigerant lines.
- Before removing lock suport, fasten radiator to body
- To remove radiator, fasten condenser to the body.


Installing
Installation is carried out in the reverse order of the removal procedure

Note the following during installation:
Engine coolant, filling. Cooling System, Draining and Filling