Withdrawal
Warnings: Drained coolant must be collected and disposed of.
When opening the expansion tank cap on a hot engine, care must be taken, as escaping vapors can cause severe burns. To do this, close the cap of the expansion tank with a thick layer of cloth and slowly unscrew the cap until a hissing sound is heard. After the hiss stops, slowly unscrew and remove the cap from the expansion tank.
Install a VAG 1306 receiving pan under the engine to collect the coolant.
Open the cap of the expansion tank.
Remove front bumper.
Pic. 3.1–1. The location of the fastening latches of the lower mudguard of the engine compartment
Release the clips and remove the lower mudguard of the engine compartment (see fig. 3.1–1).
Pic. 7–5. Radiator drain plug location
Unscrew the screw plug from the radiator (see fig. 7–5) and drain the coolant. Insert a hose instead of the screw plug to prevent coolant from spilling.
Pic. 7–31. Electrical connector location (1) temperature sensor for turning on the fan and clamp (2) coolant hose fittings
Loosen clamp 2 (pic. 7–31), remove the hose and drain the coolant.
In the lower left part of the radiator, disconnect the electrical connector 1 of the fan activation temperature sensor.
Pic. 3.1–10. Air outlet location (1) and air intake (2) near the front of the engine
Separate air intake 2 (see fig. 3.1–10) from the front cross member and remove it together with the air pipe 1.
Pic. 7–32. The location of the nuts of the upper fastening to the front cross member and the hose clamp to the radiator
Loosen clamp (pic. 7–32) and remove the top hose from the radiator.
Unscrew the two nuts of the upper fastening to the front cross member (see fig. 7–32).
Remove decorative trims from headlights.
Pic. 7–33. Location of fixing screws (2, 5) headlight trim brackets and nuts (1, 3, 4, 6) radiator mounts
Unscrew screws 2 and 5 (pic. 7–33) mounting brackets for headlight trims
Unscrew four nuts of fastening 1, 3, 4 and 6 of a radiator.
Pic. 7–34. Electrical connector location
Disconnect the electrical connector behind the left headlight (pic. 7–34)
Pic. 7–35. Bolt location (1, 2) heat exchanger mountings
Unscrew bolts 1 and 2 (pic. 7–35) heat exchanger mountings.
Unscrew the tube of the cooling system of the power steering system and, without disconnecting, move it to the side.
Unscrew the two nuts at the bottom of the radiator, shown by the arrows in fig. 7–35.
Remove the heat exchanger from the bracket and move it to the side.
Tilt the radiator and lift it up out of the engine compartment.
Examination
If the radiator was removed due to a reduction in throughput, wash it with a jet of water in two directions and blow it out with compressed air.
If the radiator is leaking, do not attempt to weld or solder the leak, as this will damage the plastic parts of the radiator.
Minor radiator leaks can be repaired with sealant.
Check the condition of the lower rubber radiator mounts and replace if necessary.
Installation
Installation is carried out in the reverse order of removal.
Install front bumper.
Fill with coolant.
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