Radiator: Service and Repair

Radiator and Coolant Fan, Removing and Installing




Special tools
^ VAG 1306 Drip tray
^ VAG1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.) or equivalent
^ VAG1921 Spring clip pliers
^ Anti-freeze tester (not shown)




Component View
1. Radiator
2. O-ring - Always replace
3. Coolant hose, upper - Attached to radiator with clip
4. Connector
5. Retaining clip
6. A/C Cutout Thermal Switch -F163
7. Coolant hose connection from connector on cylinder head
8. Coolant hose connection from connector on cylinder head/connector
9. Coolant hose connection from ATF cooler - Only on vehicles with automatic transmission
10. Electrical connector, Black 2-pin connector
11. Cap - test pressure 1.4 to 1.6 bar (20 to 23 psi)
12. Mounting Bolts 10 Nm (7 ft. lbs.)
13. Coolant expansion tank
14. Coolant hose connection from connector to radiator for EGR/connector
15. Coolant hose connection to cylinder head
16. Fan shroud
17. Right coolant fan -V35-
18. Fan bracket - Optional equipment
19. Retaining clip - ensure it is seated securely
20. Coolant fan -V7-
21. Bracket for radiator fan connector
22. Lower Coolant hose - attached to radiator with clip
23. Electrical connector, Black 3 pin connector
24. Coolant Fan Control (FC) Thermal Switch -F18-
25. Bracket for radiator comes in different versions - observe installation position


Removing
- Remove front bumper.
- Remove coolant hoses from radiator.
- Disconnect electrical connectors from coolant thermal switch and coolant fan.
- Move lock support into service position.
- Remove radiator mounting bolts and take out radiator with coolant fan downward.

A/C system, additional removal information

WARNING: Do NOT open A/C refrigerant circuit.

Note: Be careful not to stretch, kink or bend condenser and refrigerant lines and hoses.

- Remove retaining clamp(s) from refrigerant lines.
- Remove condenser from radiator and secure to lock support.


Installing
Install in reverse order of removal but note the following:
- Always replace O-ring
- Bracket for radiator comes in different versions. Note installation position.
- Lower Coolant hose is attached to radiator with clip
- Ensure Retaining Clip is seated securely
- Engine coolant, filling