Table of contents: 3.2 TDI engines 1st generation ↓ 3.2 TDI SCR engines ↓ Engines 3.2 TDI 2nd generation ↓ 4.2L TDI engines ↓
Caution: After installing a new radiator, add fresh coolant.
3.2 TDI engines 1st generation
1. Turn off the ignition and remove the key from the lock.
2. Remove the upper engine cover, the panel above the radiator and the front sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
3. Disconnect the air hoses (1 and 4 in the illustration), unscrew the bolts (2 and 3) and remove the lower air tube.
3.3. Connections and fastening of the lower air tube.
4. Unscrew the bolts (2 and 3 in illustration 26.11 Chapter 2), disconnect the air tube from the air inlet hoses (1 and 4) and remove the tube downwards.
5. Remove the air hose (see illustration 4.16 Chapter 2).
6. Disconnect the connector (1 in the illustration), unscrew the bolts (2-4) and remove the air pipe from the intercooler.
3.6. Connector (1) and fasteners (2-4) of the air tube.
7. Disconnect the upper air hose at the following locations (1 and 2 in Illustration 4.21 of Chapter 2) and remove the lower air hose (3).
8. Disconnect the connectors (1 and 2 in the illustration) and move the electrical wiring to the side.
3.8. Removing the radiator shroud.
Press the locking tabs on the left and right sides of the shroud and pull the shroud out of the engine compartment. If necessary, after removing the casing, the fans can be removed (see paragraph 9) and a radiator (see paragraphs 10-18).
9. Move the electrical wiring to the side and unscrew the bolts (1-4 and 8 in the illustration) and remove fan No. 2 "V177" with its control unit "J671".
3.9. Fastening the radiator fans.
Unscrew the bolts (5-7) and remove the fan "V7" with its control unit "J293".
10. Drain the coolant (see section 2).
11. Unhook the hose from the air cleaner cover (1 in illustration 15.7 Chapter 2) ventilation of the front differential. Disconnect the connector (3) of the MAF sensor "G70", disconnect the air hose from the turbocharger (clamp 4), release the fasteners (2) and remove the upper section of the air cleaner.
12. On models with air suspension, use a screwdriver to press the retaining ring (1 in illustration 4.24 Chapter 2) forward from the connection. Press the ring (2) in the direction of the arrows and remove the ventilation hose (3) from the air cleaner cover. If necessary, to improve access, you can remove the electrical connector for lambda probe No. 2 "G108" from the bracket on the right suspension strut.
13. Disconnect the upper left coolant hose from the radiator (see illustration 4.20 Chapter 2).
14. Remove the radiator retaining elements on the left and right by pressing the tab from below (see illustration).
3.14. Removing the radiator retaining element.
15. Remove the bolts (2 in the illustration) on the left and right sides of the front panel, unhook the radiator and tilt it back.
3.15. Bolt (2) on the front panel.
16. Unscrew the bolt (2 in the illustration) on the rear side of the radiator and disconnect the power steering fluid cooler (1) from the refrigeration unit condenser without disconnecting the power steering fluid lines.
3.16. Bolt (2) on the rear side of the radiator for fastening the power steering fluid cooler (1).
17. Unscrew the bolt (1 in the illustration) on the back of the radiator, press the clamps (2 and 3) and remove the ATF radiator (4) from the radiator without disconnecting the ATF hoses.
3.17. Removing the ATF radiator (4).
18. Remove the bolts (3 in the illustration) on the back of the radiator, press the clamps (2 and 4) and separate the condenser (1) of the refrigeration unit from the radiator without disconnecting the refrigerant lines.
3.18. Removing the condenser (1) of the climate control system.
Remove the radiator from above.
19. Installation is carried out in reverse order. Tighten the condenser, ATF radiator, and power steering cooler fasteners to 9 Nm on the radiator. Tighten the radiator fasteners on the front panel to 6.5 Nm. Tighten the fan fasteners to 4 Nm. Install the shroud until its retaining tabs engage. Tighten the air tube fasteners to the intercooler, bracket and radiator shroud to 9 Nm.
3.2 TDI SCR engines
20. The details of installing the radiator and its casing with fans are shown in the illustrations.
3.20a. Radiator installation details for models up to 05.2010:
1 - Power steering fluid cooling pipe;
2 - Refrigeration unit condenser;
3 - Holders;
4 - Coolant pipe for fuel cooling;
5, 7, 29, 32 - Bolt, 8 Nm;
6 - Coolant hose for fuel cooling circuit;
8 - Bushing;
9, 14 - Spacer;
10 - Fuel cooler;
11 - Bolt in the bleed hole, 1.5-3.0 Nm;
12 - Plug;
13 - Radiator;
15 - Bolt, 5.5 Nm;
16, 20, 23 - Sealing ring, subject to replacement;
17, 21, 22 - Coolant hose;
18, 27 - Retainer;
19 - Radiator outlet temperature sensor "G83";
24 - Rubber buffer;
25 - Radiator support locking device;
26 - Washer;
28 - ATF radiator;
30 - Air duct (only the left side is shown);
31 - Bolt, 2.5 Nm.
3.20b. Radiator installation details for models from 06.2010:
1 - Power steering fluid cooling pipe;
2 - Refrigeration unit condenser;
3 - Holders;
4 - Radiator;
5 - Spacer;
6 - Bolt, 5.5 Nm;
7, 11, 14 - O-ring, subject to replacement;
8, 12, 13 - Coolant hose;
9, 18 - Retainer;
10 - Radiator outlet temperature sensor "G83";
15 - Rubber buffer;
16 - Radiator support locking device;
17 - Washer;
19 - ATF radiator;
20, 23 - Bolt, 8 Nm;
21 - Air duct (only the left side is shown);
22 - Bolt, 2.5 Nm.
3.20s. Fan and radiator shroud installation details:
1 - Fan "V7" with control unit "J293";
2 - Fan No. 2 "V177" with control unit No. 2 "J671";
3 - Radiator shroud 4.5 Bolt, 10 Nm.
21. Turn off the ignition and remove the key from the lock.
22. Remove the upper engine cover, the panel above the radiator and the front sound insulation panel under the engine compartment (see section 19 of Chapter 1).
23. For models from 06.2010, go to paragraph 28.
24. Unscrew the bolts (witharrows in illustration 16.7 Chapter 2) lower air tube.
25. Pull out the lock (see illustration), disconnect the air hose and move it back.
3.25. Air hose clamp.
26. Remove the bolts (2, 4 and 5 in the illustration).
3.26. Fastening and connections of the air tube.
27. Move the coolant hose away from the upper air pipe. Remove the bolts (1, 2 and 4 in the illustration), separate the upper air pipe from the intercooler and move it back without disconnecting the air hose (3).
3.27. Removing the upper air tube.
Go to paragraph 33.
28. Disconnect the air hoses (1 and 4 in Illustration 3.3), unscrew the bolts (2 and 3) and remove the lower air tube.
29. Remove the bolts (2 and 3 in illustration 26.11 Chapter 2), loosen the clamps (1 and 4) and disconnect the air hoses. Remove the air tube from underneath.
30. Loosen the clamps (see illustration 4.16 Chapter 2) and remove the air hose.
31. Disconnect the connector (1 in illustration 3.6), unscrew the bolts (2-4) and remove the air pipe from the intercooler.
32. Pull out the lock (1 in illustration 4.21 Chapter 2), loosen the clamps (2 and 3) and disconnect the air hoses.
33. Disconnect the connectors (1 and 2 in Illustration 3.8) and move the electrical wiring to the side. Press the locking tabs on the left and right sides of the shroud and pull the shroud out of the engine compartment. If necessary, after removing the casing, the fans can be removed (see paragraph 9) and a radiator (see below).
34. Drain the coolant (see section 2) and remove the air cleaner filter element (see Section 16 of Chapter 1). For models from 06.2010, go to paragraph 38.
35. Loosen the clamps (1-3 in illustration 15.11 Chapter 2) and disconnect the air hoses.
36. Move the coolant hose away from the front center air pipe. Disconnect the connector (1 in the illustration) boost pressure sensor, loosen the clamp and disconnect the air hose.
3.36. Boost pressure sensor connector (1).
Separate the front central air tube together with the activator "V275" of the valve No. 2 of the intake manifold.
37. Disconnect the connector (2 in illustration 16.7 of Chapter 2), pull out the clamp (1), loosen the clamps (3 and 4) and remove the air hoses. Remove the lower air tube.
38. Pull out the lock (see illustration 4.20 Chapter 2) and disconnect the upper coolant hose from the radiator.
39. Follow the steps described in paragraphs 14-19.
Engines 3.2 TDI 2nd generation
40. The details of installing the radiator and its casing with fans are shown in the illustrations.
3.40a. Radiator installation details:
1 - Power steering fluid cooling pipe;
2 - ATF radiator;
3, 13, 21, 22 - Retainer;
4, 5 - Air ducts, only the right side is shown;
6 - Radiator;
7 - Spacer;
8 - Bolt, 5.5 Nm;
9 - Air duct;
10, 12, 17 - O-ring, subject to replacement;
11, 15, 16 - Coolant hose;
14 - Radiator outlet temperature sensor "G83";
18 - Radiator support locking device;
19 - Rubber buffer;
20 - Washer;
23 - Refrigeration unit condenser.
3.40b. Fan and radiator shroud installation details.
1, 2 - Bolt, 10 Nm;
3 - Bolt, 5 Nm;
4 - Radiator shroud;
5 - Fan No. 2 "V177" with control unit No. 2 "J671";
6 - Fan "V7" with control unit "J293".
41. Removal of the fans and radiator shroud is carried out in the same way as on 3.2 TDI engines of the 1st generation (see paragraphs 1-9). The following describes the procedure for removing the radiator (after removing its casing).
42. Drain the coolant (see Section 2) and remove the air cleaner filter element (see Section 16 of Chapter 1).
43. Pull out the lock (see illustration 4.20 Chapter 2) and disconnect the upper coolant hose from the radiator.
44. Follow the steps described in paragraphs 14-19.
4.2L TDI engines
45. The details of installing the radiator and its casing with fans are shown in the illustration.
3.45. Radiator installation details.
1 - Power steering fluid radiator;
2, 3, 21, 27 - Retainer;
4 - Coolant pipe, for the fuel cooling circuit;
5, 7, 29, 31 - Bolt, 8 Nm;
6 - Coolant hose, for fuel cooling circuit;
8, 14 - Spacer;
9 - Fuel cooling radiator;
10 - Bolt in the bleed hole;
11 - Lid;
12 - Coolant hose, to the expansion tank;
13 - Bolt, 5.5 Nm;
15 - Radiator;
16, 18, 20 - Sealing ring, subject to replacement;
17 - Coolant hose, different versions available;
19 - Coolant hose;
22 - Sensor "G83" coolant temperature at the radiator outlet;
23 - Coolant hose, only on CCFA/CCFC engines;
24 - Radiator support locking device;
25 - Rubber buffer;
26 - Washer;
28 - ATF radiator;
30 - Air conditioning system condenser.
Note: Items (4-11) are only available on the CCFC engine. Radiator shroud and fan installation details are shown in Figure 3.20c.
46. Remove the upper engine cover, the panel above the radiator and the front sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
47. Loosen the clamps and remove the air hose (see illustration 35.19 Chapter 2).
48. Disconnect the connector (arrow in the illustration) boost pressure sensor "G31", unscrew the bolts (1 and 3) and remove the connection from the left side of the intercooler.
3.48. Connector (arrow) of sensor G31 and fasteners (1 and 3) of intercooler connection.
49. Move the coolant hose away (see illustration 35.16 in Chapter 2) to the side.
50. Loosen the clamp (1 in illustration 35.15 Chapter 2) and disconnect the coolant hose. Unscrew the bolts (arrows) and remove the connection on the right side of the intercooler.
51. On the CCFC engine, disconnect the connectors (2 and 3 in the illustration), unscrew the bolts (1) and place the throttle module No. 2 "J544" with the intake air heater flange No. 2 "Z112" on the engine.
3.51. Connectors (2 and 3) and bolts (1) of throttle module No. 2.
52. Disconnect the connectors (2 and 3 in the illustration) and move the electrical wiring to the side.
3.52. Removing the radiator shroud.
Remove the bolts (1 and 4-6), press the locking tabs on the left and right sides of the casing and pull it out of the engine compartment. If necessary, after removing the casing, the fans can be removed (see paragraph 53) and a radiator (see paragraphs 54-69).
53. Move the electrical wiring to the side and unscrew the bolts (1-3 in the illustration) and remove fan No. 2 "V177".
3.53. Fan fastenings.
Unscrew the bolts (4-6) and remove the fan "V7".
54. Drain the refrigerant (see Part B of Chapter 3) and coolant (see section 2).
55. On CCFA/CCFC engines, remove the EGR radiator pump "V400" together with the bracket (see Section 5) and disconnect the coolant hose (2 in illustration 35.6 Chapter 2).
56. Lift the retainer and disconnect the coolant hose from the top of the radiator (see illustration 35.20 Chapter 2).
57. Loosen the clamp (1 in illustration 35.21 Chapter 2) and disconnect the air tube from the left air cleaner cover. Disconnect the connector (2) of the MAF sensor No. 2 "G246", release the clips (3) and remove the air cleaner cover.
58. Disconnect the connector (3 in illustration 36.5 Chapter 2), loosen the clamps (2 and 4) and remove the left air pipe.
59. On BTR/CCFA engines, disconnect the connector (1 in the illustration), unscrew the bolts (3) and remove the throttle module "J338" with the connection.
3.59. Throttle body module installation details (BTR/CCFA).
60. On CCFC engines, disconnect the connectors (1 and 3 in the illustration), remove the bolts (2) and place the throttle module "J338" together with the intake air heater connection "Z111" on the engine.
3.60. Connectors (1 and 3) and bolts (2) of the throttle control module (CCFC).
61. Remove the tie (arrow in illustration 35.11 Chapter 2) and move the electrical wiring away from the air cleaner housing.
62. Remove the right air cleaner cover as described in paragraphs 10-13 of Chapter 1.
63. Disconnect the connector (5 in illustration 35.49 Chapter 2), loosen the clamps (3 and 4) and remove the right air tube.
64. Disconnect the refrigerant lines (1 and 2 in Illustration 35.7 Chapter 2) from the condenser and seal the open holes to prevent dirt from getting into the circuit.
65. Unscrew the bolt (1 in illustration 3.17) on the back of the radiator, press the clamps (2 and 3) and remove the ATF radiator (4) from the radiator without disconnecting the ATF hoses.
66. Remove the radiator retaining elements on the left and right by pressing the tab from below (see illustration 3.14).
67. Disconnect the coolant hose (1 in illustration 3.15), remove the bolts (2) on the left and right sides of the front panel and tilt the top edge of the radiator backwards.
68. Remove the bolt (2 in illustration 3.16) on the rear side of the radiator and disconnect the power steering fluid cooler (1) from the refrigeration unit condenser without disconnecting the power steering fluid lines.
69. Remove the bolts (3 in illustration 3.18) on the back of the radiator, press the clamps (2 and 4) and separate the condenser (1) of the refrigeration unit from the radiator. Remove the radiator from above.
70. Installation is carried out in reverse order.